ERA Standard Specs 2013

THE FEDERAL DEMOCRATIC REPUBLIC OF
ETHIOPIAN ROADS AUTHORITY
Standard Technical Specifications
and Method of Measurement
for RoadWORKS
2013
Standard Technical Specification and Method of Measurement Foreword
Foreword
The road network in Ethiopia provides the dominant mode of freight and passenger transport and
thus plays a vital role in the economy of the country. The network comprises a huge national asset
that requires adherence to appropriate standards for design, construction and maintenance in order
to provide a high level of service. As the length of the road network is increasing, appropriate
choice of methods to preserve this investment becomes increasingly important.
In 2002, the Ethiopian Roads Authority (ERA) first brought out road design manuals and standard
technical specifications to provide a standardised approach for the design, construction and
maintenance of roads in the country. Due to technological development and change, these
manuals and specifications require periodic updating. This current version of the standard technical
specification has been updated taking due consideration of the revisions incorporated into the
prevailing version of the various road design manuals that make particular reference to the
prevailing conditions in Ethiopia and reflects the experience gained through activities within the
road sector during the years since 2002. Completion of the review and updating of the manuals
was undertaken in close consultation with the federal and regional roads authorities and the
stakeholders in the road sector including the contracting and consulting industry.
Most importantly, in supporting the preparation of the documents, a series of thematic peer review
panels were established that comprised local experts from the public and private sector who
provided guidance and review for the project team.
These standard technical specifications supersede the ERA Standard Technical Specifications of
2002.
On behalf of the Ethiopian Roads Authority I would like to take this opportunity to thank DFID,
Crown Agents and the AFCAP team for their cooperation, contribution and support in the revision of
the specifications and supporting documents for Ethiopia. I would also like to extend my gratitude
and appreciation to all of the industry stakeholders and participants who contributed their time,
knowledge and effort during the development of the documents and specifications. Special thanks
are extended to the members of the Peer Group whose active support and involvement guided the
authors of the specifications and the process in general.
It is my sincere hope that these specifications in association with the various design manuals and
bidding documents will provide all users with both a standard reference and a ready source of good
practice for the design, construction and maintenance of roads, and will assist in a safe, cost
effective operation, and environmentally sustainable development of our road network.
I look forward to the practices contained in the manual and specifications being quickly adopted
into our operations, thereby making a sustainable contribution to the improved infrastructure of our
country.
Comments and suggestions are expected on all aspects of these specifications from any
concerned body, group or individual as feedback during their implementation and will be highly
appreciated.
Addis Ababa, 2013

Zaid Wolde Gebriel
Director General, Ethiopian Roads Authority
Ethiopian Roads Authority Page i

Standard Technical Specification and Method of Measurement Preface
Preface
The Ethiopian Roads Authority is the custodian of the series of technical manuals, standard
specifications and bidding documents that are written for the practicing Engineer in Ethiopia. The
series of manuals describes current and recommended practice and sets out the national
standards for roads and bridges. The manuals are based on national experience and international
practice and are approved by the Director General of the Ethiopian Roads Authority.
The prevailing version of the Standard Technical Specifications and Methods of Measurement for
Roads and Bridges forms part of this series. The complete series of documents, covering all roads
and bridges in Ethiopia, are contained within the prevailing versions of the following:
1. Geometric Design Manual

2. Site Investigation Manual
3. Geotechnical Design Manual
4. Route Selection Manual
5. Pavement Design Manual Volume I Flexible Pavements
6. Pavement Design Manual Volume II Rigid Pavements
7. Pavement Rehabilitation and Asphalt Overlay Design Manual
8. Drainage Design Manual
9. Bridge Design Manual
10. Low Volume Roads Design Manual
11. Standard Environmental Procedures Manual
12. Standard Technical Specifications and Methods of Measurement for Roadworks
13. Standard Detailed Drawings
14. Standard Bidding Documents for Road Work Contracts – A series of Bidding Documents
covering a full range from large scale projects unlimited in value to minor works with an upper
threshold of $300,000. The higher level documents have both Local Competitive Bidding and
International Competitive Bidding versions
These documents are available to registered users through the ERA website: www.era.gov.et
The following hierarchical layout and numbering system has been used:
 Series – eg Series 1000: General

 Division – eg Division 1300: Contractor’s Establishment on Site
 Clause – eg Clause 1302: General Requirements
 Sub-clause – eg Sub-clause 1302(d): Laboratory
 Sub-sub-clause – eg Sub-sub-clause 1302(d)(i): General
All Tables and Figures are described by the Clause number followed by the table or figure number
within that clause starting at 1. (eg Table 1409/1: Office Furniture).
Page ii Ethiopian Roads Authority

Updates
The standard specifications will be updated and revised from time-to-time as deemed appropriate.
Significant changes to criteria, procedures or any other relevant issues related to new policies; or
revised laws of the land; or that is mandated by the relevant Federal Government Ministry or
Agency, should apply to the standard specification from their date of effectiveness.
Other minor changes that will not significantly affect the whole nature of the specifications
contained herein will be accumulated and included in subsequent revisions of the specifications.
Changes of this nature should be incorporated into Particular or Project Specifications until a new
revision has been published.
All suggestions to improve the standard specifications should be made in accordance with the
following procedures:
1. Users of the specifications must register on the ERA website: www.era.gov.et

2. Proposed changes should be outlined on the Manual Change Form and forwarded with a
covering letter of its need and purpose to the Director General of the Ethiopian Roads
Authority.
3. The proposed modifications will be assessed by the requisite authorities in ERA in close
consultation with an Executive Review Group of relevant stakeholders.
4. Agreed changes will be approved by the Director General of the Ethiopian Roads Authority on
recommendation from the Deputy Director General (Engineering Operations).
5. All approved changes to the standard specifications will be communicated to all registered
users of the specifications and posted on the web site. In addition, all affected pages will be re-
issued with the approved revision date emanating from the Specification Change Form 1-1.
Ethiopian Roads Authority Page iii

ETHIOPIAN ROADS AUTHORITY

STANDARD TECHNICAL SPECIFICATIONS AND METHOD OF
MEASUREMENT
This area to be completed by the
ERA Director of Quality Assurance
CHANGE NO._____________
SPECIFICATION CHANGE
(SECTION NO. CHANGE NO.
_________________________
Clause
Sub-clause
Table Explanation Suggested Modification
Figure
Page
Submitted by:
Name:____________________________________Designation:___________________________
Company/Organisation Address
____________________________________________________________________
_______________________________________email:______________________Date:________
Manual Change Action
Authority Date Signature Recommended Action Approval
Registration
Director Quality Assurance
Deputy Director General Eng.Ops
Approval / Provisional Approval / Rejection of Change:

Director General ERA:__________________________________ Date: __________________
Page iv Ethiopian Roads Authority

Standard Technical Specification and Method of Measurement Acknowledgements
Acknowledgements
The Ethiopian Roads Authority (ERA) wishes to thank the UK Government’s Department for
International Development (DFID) through their Africa Community Access Programme (AFCAP) for
their support in developing the Standard Technical Specifications and Method of Measurement
which will be used by all authorities and organisations responsible for the provision of roads in
Ethiopia.
This prevailing version of the Standard Technical Specifications is based on a review of local and
international procedures and is complimentary to the updated and revised suite of ERA Design
Manuals. This version includes improvements and extensions to deal with topics that were not
included in the earlier specifications; for example relevant updates in line with the ERA Low Volume
Roads Design Manual.
From the outset, the approach to the development of the manuals and specifications was to include
all sectors and stakeholders in Ethiopia. The input from the international team of experts was
supplemented by our own extensive local experience and expertise. Local knowledge and
experience was shared through review workshops to discuss and debate the contents of the draft
manual and subsequent specifications. ERA wishes to thank all the individuals who gave their time
to attend the workshops and provide valuable inputs to the compilation of the specifications.
A Specifications Peer Group comprising specialists drawn from within the local industry was
established to provide advice and comments in the specialists’ respective areas of expertise. The
contribution of the Peer Group participants is gratefully acknowledged.
The final review and acceptance of the document was undertaken by an Executive Review Group.
Special thanks are given to this group for their assistance in reviewing the final draft of the
document.
Finally, ERA would like to thank AFCAP Core Management Group for their overall management of
the project.
Executive Review Group
No. Name Organization
1 Dr. Alemgena Araya Ethiopian Roads Authority
2 Ato Bekele Jebessa Ethio Infra Engineering plc
Ethiopian Roads Authority Page v

List of Persons Contributing to Peer Group Review
No. Name Organization

1 Ato Admasu Getachew Ethiopian Roads Authority
2 Ato Ahmed Mohammed Associated Engineering Consultants
3 Ato Alemayehu Ayele Ethiopian Roads Authority
4 Ato Amare Assefa Ethiopian Roads Authority
5 Ato Begashaw Debele Net Consult
6 Ato Bekele Jebessa Ethio Infra Engineering plc
7 Ato Bizuneh Kebebe Civil Works Consulting Engineers
8 Ato Brook Shamsu Labour Base Association
9 Ato Daniel Nebro DNH Consult
10 Ato Dereje Gezahegn Classic Consulting Engineers
11 Ato Efrem Gebre Egziabher Core Consulting Engineers
12 Ato Ezra Mersha Associated Engineering Consultants
13 Ato Frew Bekele Ethiopian Roads Authority
14 Ato Frew Terefe Ethiopian Roads Authority
15 Ato Kefargachew Kassahun Ethiopian Roads Authority
Construction Contractors Association of

16 Ato Melaku Tadesse
Ethiopia
17 Ato Melka Bekele Ethiopian Roads Authority
18 Ato Mulugeta Demissie Ethiopian Roads Authority
19 Ato Muse Belew Ethiopian Roads Authority
20 Ato Nigatu Widneh Ethiopian Roads Authority
21 Ato Shimeles Tesfaye SPICE Consult
22 Ato Shimelis Tilahun Net Consulting Engineers and Architects
23 Ato Sileshi Degefa Ethiopian Roads Authority
24 Ato Solomon Kulich Scott Wilson
25 Ato Teshome Worku CORE Consulting Engineers
26 Ato Yoseph Kidane Private
27 Dr. Alemgena Araya Ethiopian Roads Authority
28 Mr. Dick L-J WSP
29 W/ro Hiwot Mosisa Ethiopian Roads Authority
Page 0000-vi Ethiopian Roads Authority

Project Team
No. Name Organisation Role
AFCAP Coordinator for

1 Bekele Negussie ERA
Ethiopia
2 Abdo Mohammed ERA Project Coordinator
3 Frew Bekele ERA Project Coordinator
4 Rob Geddes AFCAP/Crown Agents Technical Manager
5 Les Sampson AFCAP/Crown Agents Project Director/Lead Author
6 Brian Barr AFCAP/Crown Agents Specialist Contributor
7 John Rolt AFCAP/Crown Agents Specialist Contributor
8 Gareth Hearn AFCAP/Crown Agents Specialist Contributor
9 Manaye Ewunetu AFCAP/Crown Agents Specialist Contributor
10 Colin McKenna AFCAP/Crown Agents Specialist Contributor
Addis Ababa, 2013
Zaid Wolde Gebriel

Director General, Ethiopian Roads Authority
Ethiopian Roads Authority Page vii

Standard Technical Specification and Method of Measurement Summary Table of Contents
Summary Table of Contents
Series 0000: Method of Measurement ..................................................................................................................... 1
Series 1000: General ................................................................................................................................................ 6
Series 2000: Site Clearance ................................................................................................................................. 156
Series 3000: Drainage Structures ......................................................................................................................... 165
Series 4000: Earthworks and Material Stabilisation ............................................................................................ 220
Series 5000: Sub-Base, Road Base and Gravel Wearing Course ......................................................................... 269
Series 6000: Bituminous Surfacings and Road Base ........................................................................................... 329
Series 7000: Rigid Pavements ............................................................................................................................. 453
Series 8000: Structures ........................................................................................................................................ 506
Series 9000: Ancillary Works .............................................................................................................................. 678
Series 10000: Testing Materials and Workmanship ............................................................................................. 733
Page 0000-viii Ethiopian Roads Authority

Standard Technical Specification and Method of Measurement Series 0000
Series 0000: Method of Measurement
TABLE OF CONTENTS
DIVISION 0100: PREAMBLE ....................................................................................................................... 2
0101 Description .................................................................................................................................... 2
0102 General Principles ........................................................................................................................ 2
0103 General Rules for Measurement .................................................................................................. 2
a) Units of measurements ...................................................................................................................... 2
b) Measurement of completed work ...................................................................................................... 2
c) Contract Rates ................................................................................................................................... 3
d) Meanings of certain phrases in payment Clauses .............................................................................. 3
(i) “Procuring and furnishing (Pay Item mentioned) material” ......................................................................... 3
(ii) "Placing material" ......................................................................................................................................... 3
(iii) “Procuring, furnishing and placing material” ............................................................................................... 3
e) Pay Items........................................................................................................................................... 3
f) Provisional Sums and Prime Cost Items ........................................................................................... 4
(i) Provisional Sums .......................................................................................................................................... 4
(ii) Provisional Items .......................................................................................................................................... 4
(iii) Prime Cost (PC) Items .................................................................................................................................. 4
(iv) Rate only items ............................................................................................................................................. 4
g) Variation from Specified Nominal Rates of Application or Nominal Mix Proportions .................... 4
h) Payments and Tolerances .................................................................................................................. 5
Ethiopian Roads Authority Page 0000-1

Division 0100: Preamble
0101 Description
At the end of each Division is a clause titled “Measurement and Payment” which shall collectively be
known as the “Method of Measurement”. Each such clause describes the measurement, itemisation
and item coverage to be used within the Bill of Quantities related to the items contained within the
respective Divisions.
0102 General Principles

The Bill of Quantities is intended, in the first instance, to provide information upon which tenders can
be obtained. When a Contract has been entered into, the function of the priced Bill of Quantities is to
provide for the valuation of the work executed.
The sub-headings and the item description used in the Bill of Quantities identify the work covered by
the respective items, but the exact nature and extent of the work to be performed is to be ascertained
by reference to the Drawings, Specifications and Conditions of Contract as the case may be, read in
conjunction with the items listed under the Method of Measurement. The rates and prices to be
inserted in the Bill of Quantities are to be considered as the full inclusive rates and prices for the
finished work covered by the respective items and shall include:
 Procurement and furnishing of all materials;

 Labour and supervision;
 Plant, tools and equipment;
 Wastage;
 Management of borrow areas including removal and stockpiling of topsoil for reuse, clearing
and grubbing, and removal of excess overburden;
 Transport/haulage, loading, offloading, and handling/multiple handling;
 Maintenance, precautions to avoid damage to property, cleaning and reinstatement of
adjacent ground;
 Temporary work;
 Setting out;
 Detailed working drawings;
 Testing, trial mixes, materials for testing, attendance for sampling and testing carried out by
the Engineer, and quality control including process control;
 Dealing with the flow of water;
 Overheads, profit, as well as general liabilities, obligations and risks arising from the Contract.
0103 General Rules for Measurement
a) Units of measurements
All work shall be measured in accordance with the SI System of metric units.
b) Measurement of completed work

 All distances along the centreline of the roads as shown on the Drawings are horizontal
distances which shall be used in calculating the quantities of earthworks, pavement layers,
Page 0000-2 Ethiopian Roads Authority

surfacing and paving for payment purposes. All cross sections shall be taken in a vertical
plane.
 All materials which are specified to be measured in the vehicle shall be hauled in vehicles of
such type and size that the actual contents may be readily and accurately determined. Unless
all vehicles are of uniform capacity, each vehicle shall bear a plainly legible identification mark
indicating its specific approved capacity.
 Where the quantity of bituminous and similar materials is to be paid by volume, it shall be
measured at the specified temperature.
 Structures shall be measured to the neat lines shown on the Drawings including any changes
ordered in writing by the Engineer and shall include any reinforcing steel and minor ducts up
to 150 mm in diameter.
c) Contract Rates
In computing the final contract amount, payments shall be based on actual quantities only of
authorised work done in accordance with the Specifications and Drawings. The tendered rates shall
apply, subject to the provisions of the Conditions of Contract, irrespective of whether the actual
quantities are more or less than the billed quantities.
Where no rate or price has been entered against a Pay Item in the Bill of Quantities by a tenderer, it
shall be understood that the tenderer does not require any compensation for such work.
d) Meanings of certain phrases in payment Clauses
(i) “Procuring and furnishing (Pay Item mentioned) material”

Where any of the words "supply", "procure" or "furnish (Pay Item mentioned) material” are used in the
description of a Pay Item it shall mean the supply and delivery to the point of use of all materials
required for the work covered by the particular Pay Items, including all tax, purchase costs, claims,
damages, royalties and transport costs involved. In the case of borrow materials, stone and sand, it
shall also include all negotiations with owners; royalties; excavating; producing; preparing; processing;
testing; hauling and delivering the material to the point of use; the construction, repair, maintenance
and making good after completion of all access roads; and all work required in opening, using and
finishing off borrow areas which is not covered by other Pay Items in the Bill of Quantities.
(ii) "Placing material"

The phrase "placing material" shall mean the offloading, spreading, blending, processing, watering,
mixing, shaping and compacting (where specified) the material in the road prism, sub-base, base,
shoulders, banks and bypasses; as well as procuring, furnishing, applying and admixing of water;
breaking down oversize material; removing oversize material which cannot be broken down; correcting
irregular or uneven surfaces or deficient thickness; finishing off to within the specified tolerances;
refilling test holes; and maintaining the completed work. In the case of asphalt courses and bituminous
treatments it shall also mean the heating and spraying of binder; spreading of aggregate or asphalt
mixtures; rolling, compacting and finishing off to within the specified tolerances; and maintaining the
completed work.
(iii) “Procuring, furnishing and placing material”

The phrase "procuring, furnishing and placing" shall mean "procuring and furnishing" in addition to
"placing" all as defined in sub-clauses 0103(d)(i) and (ii).
e) Pay Items
The descriptions under the Pay Items in the various Divisions of the Specifications, indicating the work
to be allowed for in the tendered prices for such Pay Items, are for the guidance of the Contractor and

do not necessarily repeat all the details of work and materials required by and described in the
Specifications.
These descriptions shall be read in conjunction with the relevant Specifications and Drawings and the
Contractor shall, when tendering, allow for his prices to be inclusive as specified in sub-
clause 0103(b).
f) Provisional Sums and Prime Cost Items
(i) Provisional Sums

The Bill of Quantities may contain certain Provisional Sums so designated and entered as a
preliminary allowance to cover the cost of work, materials, goods or services to be provided by the
Contractor and which have not been fully specified or measured; or to cover the cost of unforeseen
items of work or contingent expenditure for which no rates are applicable but for which the Contractor
is to be paid according to the applicable provisions of the Contract.
(ii) Provisional Items

Work done under a Provisional Item shall only be executed upon a written order by the Engineer which
shall also specify the method of payment. The expenditure in respect of a Provisional Item for work
ordered by the Engineer shall be entirely at his discretion and any final expenditure in respect of a
Provisional Item may be more, less or equal to the amount provided in the Bill of Quantities. Such an
item may be an alternative to another item of similar or greater quantity.
(iii) Prime Cost (PC) Items

The Bill of Quantities may contain PC Items, so designated, which are entered as a preliminary
allowance to cover the cost of work, materials, goods and services to be provided by a nominated sub-
contractor; or of articles or goods to be purchased by the Contractor in execution of a written order by
the Engineer who may designate a particular source of supply or brand of article.
No expenditure or appointment of a sub-contractor in respect of a PC Item will be authorised unless

upon the written instructions of the Engineer. The amount authorised by the Engineer shall be entirely
at his discretion and may be more, equal to or less than the amount entered in the Bill of Quantities.
Payment for a PC Item shall be as follows:
1. The amount actually paid by the Contractor to the sub-contractor or supplier, as the case may
be, in execution of the Engineer's written order, plus
2. A percentage of the amount actually paid to the sub-contractor or supplier by the Contractor to
cover all his charges and profits.
The Contractor shall not be entitled to any further payments or to a fee, commission, rebate, discount
or similar payment or consideration from the supplier or sub-contractor and shall disclose and subtract
such amounts from the amount claimed under (1) above.
(iv) Rate only items

In the Bill of Quantities, where no quantity is given but a "rate only" is required, the Contractor shall fill
in a rate or price which will constitute payment for any work which may be done under this item. Such
a "rate only" item is used where it is estimated that little or no work will be required under the item; or
where the item is to be considered as an alternative for another item where a quantity is given; or for
variations in rates of application or mix proportions.
g) Variation from Specified Nominal Rates of Application or Nominal Mix Proportions

The various Divisions of the Technical Specifications prescribe nominal rates of application or nominal
mix proportions for materials such as bituminous materials, aggregates, mineral fillers, stabilising

agents, paints and the like. Tenderers shall base their Tenders on these nominal rates of application
and mix proportions.
Allowance is made in the various Divisions of the Technical Specifications where such rates of
application and mix proportions are given, for variations arising out of different rates of application or
mix proportions ordered by the Engineer to suit the materials and conditions on site in every particular
case.
Where the actual rates of application or mix proportions, used in the Works, vary from the nominal
specified rates or proportions, adjustment of compensation will be made:
 As a payment to the Contractor in respect of any authorised increase in quantities from those
specified which has been ordered in writing by the Engineer; or
 As a refund to the Employer in respect of the decrease in quantities from those specified
whether such decrease results from an authorised decrease in the rates of application or mix
proportions, or whether it results from unauthorised reductions on the part of the Contractor.
Payment for a varied rate shall be based on the actual rate of application used, provided that this does
not exceed the rate of application ordered by the Engineer plus any tolerance in the rate of application
allowed. If the actual rate of application exceeds the above, payment shall be based on the rate of
application ordered plus any tolerance allowed.
If the actual rate of application is below the rate of application ordered, payment shall be based on the
actual rate of application regardless of any tolerance allowed. Notwithstanding the above the Engineer
shall have the full authority to condemn work which has been constructed at variance with the
Specifications or the rates of application ordered by him.
The Employer shall be refunded for any decrease in the specified rates of application or mix
proportions at the same price per unit of measurement as that tendered by the Contractor for
additional materials required by an increase in the rates of application of mix proportions.
h) Payments and Tolerances

The work specified in the Specifications shall comply with the various dimensional and other
tolerances specified in each case. Where no tolerances are specified, the standard of workmanship
shall be in accordance with normal good practice. No representation is made that the full specified
tolerances will be available independently of each other and the Contractor is cautioned that the liberal
or full use of any one or more tolerances may deprive him of the full or any use of tolerances relating
to other aspects of the work. The latter would apply particularly in respect of level tolerances on layer
work and the related requirements regarding layer thickness.
In the description of certain Pay Items, where it is stated that quantities will be determined from the
"authorised" dimensions, this shall be taken to mean the dimensions as specified or shown on the
Drawings or, if changed, as finally instructed by the Engineer, without any allowance for tolerances
specified. If the work is therefore constructed in compliance with the "authorised" dimensions plus or
minus any tolerances allowed, quantities will be based on the "authorised" dimensions regardless of
the actual dimensions to which the work is constructed.
Where the work is not constructed in accordance with the "authorised" dimensions, plus or minus any
tolerances allowed, the Engineer may nevertheless in his sole discretion accept the work for payment.
In such cases no payment will be made in respect of quantities of work or material in excess of those
calculated from the "authorised" dimensions and where the actual dimensions are less than the
"authorised" dimensions, minus any tolerance allowed, quantities for payment shall be based on the
actual dimensions as constructed.

Series 1000: General
TABLE OF CONTENTS
DIVISION 1100: TERMS, DEFINITIONS AND ABBREVIATIONS ....................................................................... 14
1101 Description .................................................................................................................................. 14
1102 Terms and Definitions ................................................................................................................. 14
1103 Abbreviations .............................................................................................................................. 31
DIVISION 1200: GENERAL REQUIREMENTS AND PROVISIONS .................................................................... 34
1201 Scope .......................................................................................................................................... 34
1202 Workmanship and Quality Control .............................................................................................. 34
1203 Approval of Completed Works .................................................................................................... 35
1204 Setting Out of Work and Protection of Survey Monuments ........................................................ 36
1205 Standards .................................................................................................................................... 37
(a) Equivalency of Standards and Codes .............................................................................................. 37
(b) Compliance with Specified Standards and Codes ...........................................................................37
(c) Supply of Standards and Codes .......................................................................................................37
(d) Trade Names ...................................................................................................................................37
(e) Materials and Manufactured Articles .............................................................................................. 37
1206 Protection of the Works and Requirements to be met before Construction of New Work on Top of
Completed Work is Commenced ................................................................................................ 38
(a) Temporary Drainage Works .............................................................................................................38
(b) Borrow Pit Material ......................................................................................................................... 38
(c) Fill and Cut Slope Repair ................................................................................................................38
(d) Water Ingress at Excavations...........................................................................................................38
(e) Protection of Layer Work ................................................................................................................38
(f) Damage to Completed Layers .........................................................................................................38
1207 Existing Public Utilities ................................................................................................................ 39
1208 Remedial Work............................................................................................................................ 40
(a) Earthworks ......................................................................................................................................40
(b) Stabilising ........................................................................................................................................41
(c) Local defects in pavement layers ....................................................................................................41
(d) Concrete ..........................................................................................................................................41
1209 Water ........................................................................................................................................... 41
(a) Water Quality Type A ......................................................................................................................42

(b) Water Quality Type B ...................................................................................................................... 42
1210 Use of Explosives and Demolition .............................................................................................. 42
(a) Compliance with Laws and Regulations ......................................................................................... 43
(b) Personnel Responsible for Blasting ................................................................................................ 43
(c) Directions for use ............................................................................................................................ 43
(d) Licenses .......................................................................................................................................... 44
(e) Storage ............................................................................................................................................ 44
(f) Precautions to be taken ................................................................................................................... 44
1211 Photographic Records ................................................................................................................ 45
1212 Working Drawings ....................................................................................................................... 46
1213 As-Built Drawings ....................................................................................................................... 46
1214 Project Signboard ....................................................................................................................... 47
1215 Occupational Health and Safety Programme ............................................................................. 47
(a) First-Aid Facilities .......................................................................................................................... 48
(b) Accident Prevention Officer ........................................................................................................... 48
(c) Epidemics........................................................................................................................................ 48
(d) Fire Protection................................................................................................................................. 48
(e) Records of Health and Safety .......................................................................................................... 48
(f) Reporting of Accidents.................................................................................................................... 48
1216 Participation of Women............................................................................................................... 48
1217 Temporary Diversions ................................................................................................................. 49
1218 Haul and Access Roads ............................................................................................................. 49
1219 Royalties ..................................................................................................................................... 49
1220 Site Meetings and Reporting ...................................................................................................... 49
1221 Measurement and Payment ....................................................................................................... 50
DIVISION 1300: CONTRACTOR'S ESTABLISHMENT ON SITE ....................................................................... 51
1301 Scope .......................................................................................................................................... 51
1302 General Requirements ............................................................................................................... 51
a) Camps, equipment and testing facilities .......................................................................................... 51
b) Legal relations and responsibility to the public .............................................................................. 53
c) Electricity Supply............................................................................................................................ 53
d) Laboratory ....................................................................................................................................... 53
e) Handing over of the Site ................................................................................................................. 53
1303 Measurement and Payment ....................................................................................................... 54

DIVISION 1400: ACCOMMODATION, SERVICES, AND ATTENDANCE FOR THE ENGINEER'S STAFF ................. 55
1401 Scope .......................................................................................................................................... 55
1402 General ....................................................................................................................................... 55
a) Ownership of Engineer’s Site Facility ............................................................................................ 56
1403 Office and Laboratory Accommodation ....................................................................................... 56
a) General ............................................................................................................................................56
b) Air Conditioning Units ....................................................................................................................58
c) Offices .............................................................................................................................................58
d) Laboratories.....................................................................................................................................59
e) Areas around Offices ....................................................................................................................... 60
f) Communication System for the Engineer ........................................................................................ 60
1404 Housing Accommodation for the Engineer ................................................................................. 62
a) General ............................................................................................................................................62
(i) Type A houses ............................................................................................................................................. 62
(ii) Type B houses ............................................................................................................................................. 62
(iii) Type C houses ............................................................................................................................................. 62
(iv) Type D house (Mess Hall)........................................................................................................................... 62
b) Description ......................................................................................................................................62
c) Maintenance ....................................................................................................................................63
1405 Services ...................................................................................................................................... 63
a) Sanitary arrangements .....................................................................................................................63
b) Water, electricity, gas and other chemicals ......................................................................................64
c) Maintenance ....................................................................................................................................65
d) Assistance to the Engineer ..............................................................................................................65
e) Safety and Emergency Equipment ..................................................................................................65
1406 Vehicles ....................................................................................................................................... 65
a) General ............................................................................................................................................65
b) Types of Vehicles............................................................................................................................. 65
(i) Vehicle Type A ............................................................................................................................................ 66
(ii) Vehicle Type B ............................................................................................................................................ 66
(iii) Vehicle Type C ............................................................................................................................................ 66
1407 Attendance .................................................................................................................................. 66
1408 Temporary Facilities and Vehicles for the Engineer .................................................................... 66
1409 Tables .......................................................................................................................................... 68

1410 Measurement and Payment ..................................................................................................... 109
DIVISION 1500: TRAFFIC M ANAGEMENT .................................................................................................114
1501 Scope .........................................................................................................................................114
1502 General Requirements ..............................................................................................................114
a) General .......................................................................................................................................... 114
b) Default by the Contractor .............................................................................................................. 116
c) Minimum Vertical Clearance ........................................................................................................ 116
d) Property and Survey Monuments .................................................................................................. 116
e) Access to Properties ...................................................................................................................... 116
f) Public services .............................................................................................................................. 116
g) Temporary works .......................................................................................................................... 116
h) Approval of Temporary Traffic Diversions ................................................................................... 117
1503 Traffic Barriers, Signing and Lighting.........................................................................................117
a) Traffic Barriers .............................................................................................................................. 117
b) Traffic Signing .............................................................................................................................. 117
c) Traffic Lights ................................................................................................................................ 117
1504 Construction of Temporary Traffic Diversions ............................................................................117
a) Maximum Length.......................................................................................................................... 118
b) Minimum Width ............................................................................................................................ 118
1505 Accommodation of Traffic Where the Road Is Constructed In Half Widths ...............................118
1506 Temporary Drainage Works .......................................................................................................118
1507 Earthworks for Traffic Diversions ...............................................................................................119
1508 Gravelling of Traffic Diversions or of Existing Roads used as Traffic Diversions ......................119
1509 Selected Gravel Layers, Crushed Stone or Asphalt Base, Stabilisation, and Road Markings
required for Bitumen-Surfaced Temporary Diversions ..............................................................119
1510 Existing Roads used as Temporary Diversions .........................................................................119
1511 Bitumen Surfaced Temporary Diversions ..................................................................................119
1512 Maintenance of Gravel Traffic Diversions ................................................................................. 120
1513 Maintenance of Existing Roads ................................................................................................ 120
1514 The Contractor's use of Traffic Diversions ................................................................................ 120
1515 Removal of Traffic Diversions ................................................................................................... 120
DIVISION 1600: SOCIAL, HEALTH, SAFETY AND ENVIRONMENTAL PROTECTION AND MITIGATION MEASURES
123
1601 Scope ........................................................................................................................................ 123

1602 General Requirements .............................................................................................................. 123
1603 Site Environmental and Social Management Plan (SESMP) ................................................... 123
1604 Landscape Preservation ........................................................................................................... 125
(a) General ..........................................................................................................................................125
(b) Temporary Traffic Diversions and Haul Roads .............................................................................126
(c) Contractor’s Facilities ...................................................................................................................126
(d) Blasting Precautions ...................................................................................................................... 126
(e) Quarries, Borrow Pits, Plant and Storage Areas ............................................................................126
(f) Spoil Disposal ............................................................................................................................... 128
1605 Soil Erosion Control .................................................................................................................. 129
(a) General ..........................................................................................................................................129
(b) Construction ..................................................................................................................................130
1606 Preservation of Trees and Shrubbery ....................................................................................... 131
(a) Preservation ...................................................................................................................................131
(b) Repair or Treatment of Damage ....................................................................................................131
(c) Replacement ..................................................................................................................................131
1607 Prevention of Water Pollution ................................................................................................... 132
(a) General ..........................................................................................................................................132
(b) Compliance with Laws and Regulations ....................................................................................... 133
1608 Abatement of Air, Dust, Noise and Light Pollution .................................................................... 134
(a) Abatement of Air Pollution ...........................................................................................................134
(b) Dust Abatement ............................................................................................................................. 134
(c) Noise Abatement ........................................................................................................................... 135
(d) Light Abatement ............................................................................................................................ 135
1609 Preservation of Historical, Archaeological and Cultural Remains ............................................. 135
1610 Pesticides .................................................................................................................................. 135
1611 Clean-up and Disposal of Waste Materials ............................................................................... 136
(a) Clean-up ........................................................................................................................................136
(b) Disposal of Waste Material ...........................................................................................................136
1612 Summary of Environmental Mitigation Measures ..................................................................... 137
(a) Air Pollution ..................................................................................................................................137
(b) Noise Pollution .............................................................................................................................. 137
(c) Traffic and Other Safety Issues .....................................................................................................138
(d) Camp Sites ....................................................................................................................................138

(e) Quarry Sites, Borrow Areas and Diversion Roads ........................................................................ 139
(f) Slope Instability and Soil Erosion ................................................................................................. 140
(g) Water and Soil Resources.............................................................................................................. 140
(h) Flora .............................................................................................................................................. 141
(i) Fauna ............................................................................................................................................. 141
(j) Farmland ....................................................................................................................................... 142
(k) Crossing Structures, Access Roads and other Services ................................................................. 142
(l) Culverts and Bridges ..................................................................................................................... 142
(m) Labour Issues ................................................................................................................................ 143
1613 Health, Safety and Accidents .................................................................................................... 143
1614 General STD and HIV/AIDS Prevention and Control Programme ........................................... 148
1615 Liaison with Communities and Local Authorities ...................................................................... 148
(a) PLC Representatives ..................................................................................................................... 149
(b) Public Meetings ............................................................................................................................ 150
(c) Notices .......................................................................................................................................... 150
1616 Participation of Local Communities .......................................................................................... 150
(a) Compliance with Labour Law ....................................................................................................... 150
(b) Employment of Children ............................................................................................................... 151
(c) Sub-Letting of Works .................................................................................................................... 151
(d) Responsibility of Sub-Contractors ................................................................................................ 151
(e) Selection of Sub-Contractors ........................................................................................................ 151
(f) Labour Sub-Contractors ................................................................................................................ 151
(g) Recruitment of Labour .................................................................................................................. 151
(h) Reporting ...................................................................................................................................... 151
1617 Complimentary Interventions .................................................................................................... 152
1618 Measurement and Payment ...................................................................................................... 152
DIVISION 1700: OVERHAUL ................................................................................................................... 155

LIST OF TABLES
Table 1402/1: Ownership of Engineer’s Site Facilities .......................................................................... 56
Table 1409/1: Office Furniture ............................................................................................................... 68
Table 1409/2: Office Supplies and Equipment....................................................................................... 69
Table 1409/3: Laboratory Equipment..................................................................................................... 71
Table 1409/4: Laboratory Fittings and Furniture (excluding offices of the laboratory - see Table 1409/1)
...................................................................................................................................................... 99
Table 1409/5: Floor area for Engineer’s Office .................................................................................... 101
Table 1409/6: Floor area for Laboratory .............................................................................................. 101
Table 1409/7: Floor area for Housing Accommodation to the Engineer .............................................. 101
Table 1409/8: Equipment for the Engineer’s housing .......................................................................... 103

LIST OF FIGURES
Figure 1102/1: Terms and Definitions for Road Cross Section Elements ............................................. 29
Figure 1102/2: Terms and Definitions for Flexible Pavement Structure ................................................ 29
Figure 1102/3: Terms and Definitions for Rigid Pavement Structure .................................................... 30
Figure 1102/4: Terms and Definitions for Gravel Road Cross-section Elements .................................. 30

Division 1100: Terms, Definitions and Abbreviations
1101 Description
In these Specifications the following terms, words or expressions shall have the meanings hereby
assigned to them. For clarity and ease of understanding, certain cross-sectional and pavement
structural elements are illustrated in Figures 1102/1, 1102/2 and 1102/3.
1102 Terms and Definitions

Access Road
A portion of the haul route built or used during the contract period to gain access from the public road
to sources of materials or spoil areas.
Aggregate
Hard mineral elements of construction material mixtures, for example: sand, gravel (crushed or
uncrushed) or crushed rock.
Anchorage
Anchorage is the device comprising all the components and materials required for retaining the force
in a tensioned tendon and to transmit this force to the concrete of the structure.
Anchorage Reinforcement
Anchorage Reinforcement is the spiral and other reinforcement which forms part of the Anchorage and
is required for strengthening the Anchorage and/or assisting in transmitting the tendon force to the
concrete.
Angle of Slope
Unless otherwise stated, is given in terms of the ratio of the vertical difference in elevation between
any two points and the horizontal distance between them.
This ratio may also be expressed as a percentage.
Arising Tool
A tool used to round off the edge of a concrete slab.
Asphalt or Asphalt Concrete

A mixture to predetermined proportions of aggregate, filler and bituminous binder material prepared off
the road in a premix plant and usually placed by means of a paving machine. (NB – for the purpose of
these specifications the term asphalt does not apply to the bitumen used in the asphalt mixture.
Bitumen is defined separately below).
Asphalt Surfacing
The layer or layers of asphalt concrete constructed on top of the road base.
Back Fill
Excavated or imported material, which is placed and compacted in trenches and around foundations.
Base
A layer of material constructed on top of the sub-base, or in the absence thereof, the capping layer
and/or the selected sub-grade. A base may extend to outside the travelled way.
Batter Board
A board of wood fixed to posts at the top of cuttings or the bottom of embankments which indicates the
slope at which the cutting or embankment is to be constructed.

Binder
A material such as bitumen, cement or lime, which is added to and mixed into aggregate, granular
materials or soils to bind the mixture together.
Bitumen
A non-crystalline black or dark-coloured, solid or viscous mixture of complex hydrocarbons that
possesses characteristic agglomerating properties, softens gradually when heated, is substantially
soluble in trichlorethylene and is obtained from crude oil by refining processes.
Bitumen Stabilised Materials

Granular, previously cement-treated or reclaimed asphalt materials that are treated with either bitumen
emulsion or foamed bitumen to improve the strength and moisture susceptibility of a new base or sub-
base layer.
Bond breaker
Bond breaker is the coating or sheath placed on a tendon to prevent it from bonding to the
surrounding concrete.
Bond Stone
A bond stone is an elongated prismoidal stone incorporated with the longest dimension at right angles
to the face of a masonry structure to provide structural integrity.
Borrow Area/Borrow Pit

An area, within designated boundaries, outside the Permanent Works, approved for the purpose of
obtaining fill or pavement materials. A borrow pit is the excavated pit in a borrow area.
Borrow Material
Borrow material is a general term used to describe material obtained from a borrow pit.
Boulder
A fragment of rock, usually rounded by weathering or abrasion, with a minimum dimension of 300 mm.
Bridge
A structure erected over a depression, river, watercourse, railway line, road or other obstacle for
carrying motor, railway, pedestrian or other traffic or services and having a length, measured between
abutment faces along the centreline of the superstructure, of 6 metre or more.
Bursting reinforcement
Bursting reinforcement is the reinforcing steel required in and adjacent to the Anchorage zones to
resist the tensile stresses induced in the concrete by the Anchorage (s).
Cable
Cable is the tendon together with the Anchorage, sheathing and all fittings.
California Bearing Ratio (CBR)

The California Bearing Ratio (CBR) of an untreated soil or gravel as determined by means of Method
SANS 3001-GR40 of the South African National Standards (SANS) is the load in Newtons, expressed
2
as a percentage of California standard values, required to allow a circular piston of 1 935 mm to
penetrate the surface of a compacted material at a rate of 1.27 mm per minute to depths of 2.54, 5.08
and 7.62 mm. The California standard values for these depths are 13.344, 20.016 and 25.354 kN
respectively. See also the method ASTM D1883-07e2.
Camber
The transverse surface profile of a carriageway. Generally a ‘balanced camber’ describes the situation
where a single carriageway has a raised ‘crown’ in the centre and the road surface slopes down at a
regular % to each side. The purpose is to ensure that surface water drains rapidly from the road. See
‘Crossfall’ below.

Capping Layer/Selected Subgrade

A layer or layers of selected fill material of subgrade quality placed on top of the topmost embankment
layer or a layer placed on the bottom of excavations.
Carriageway
That portion of the roadway including the various traffic lanes and auxiliary lanes but excluding
shoulders.
Catch-Water Drain or Bank

A longitudinal drain or bank outside the road prism for diverting water that would otherwise flow into
the road prism.
Cemented Material
Material in an existing pavement which cannot be broken up with the tines of a type 1400 caterpillar or
similar road grader.
Cemented crushed stone is cemented material constructed with crushed stone.
An existing stabilised pavement layer will not necessarily be classified as cemented material.
Channel
A natural or artificial water course.
Characteristic strength of steel for reinforcement

Characteristic strength of steel for reinforcement is the manufacturer's guaranteed tensile strength
below which no more than 5 per cent of the test results in a statistical population shall fall.
Characteristic Strength of Concrete

The characteristic strength of concrete is that strength below which only a pre-selected proportion of
test results (i.e. 1%, 2% or 5%) are expected to fall.
Chemically Stabilised Materials

The stabilisation of soils, gravels and crushed stone for base and sub-base layers using cement or
lime.
Chippings
Chippings are single sized particles of crushed rock, crushed boulders, crushed cobbles or crushed
gravel used for surface dressing.
Class of Concrete
This is an arbitrary characterisation of concrete of various qualities or usages; usually by compressive
cube strength and nominal aggregate size. (eg 30/20 class concrete would have a 28-day minimum
compressive cube strength of 30 MPa and a nominal aggregate size of 20 mm)
Coarse Aggregate
Coarse Aggregate is material retained on the 4.75 mm sieve.
Cobble
A fragment of rock, usually rounded by weathering or abrasion, with a minimum dimension of 60 mm
and a maximum dimension of 200mm.
Coefficient of Uniformity
The coefficient of uniformity is the ratio of the sieve size through which 60% by mass of the material
passes to the sieve size through which 10% by mass passes.
Compliance Testing
Testing of the completed works to ascertain compliance of the requirements of the Specification.

Coupler
Coupler is the device comprising all components required to join up two tendons.
Crossfall
The situation where the transverse gradient is uniform from one side of the carriageway to the other.
This is typical of each part of a dual carriageway. The purpose is to ensure that surface water drains
rapidly from the road.
Crushed Particle
A crushed particle is a particle of coarse aggregate, which has at least three fractured faces when
obtained by crushing rock and boulders, and at least two fractured faces when obtained by crushing
gravel.
Crushed Ratio
The crushed ratio is the percentage of crushed particles of coarse aggregate in the total number of
particles of coarse aggregate.
Culvert
A drainage structure which provides an opening under the carriageway or median for the passage of
water.
Curing Compound
A liquid which is applied as a surface coating to (newly placed) concrete and hardens to form a
membrane that inhibits the evaporation of moisture from the concrete.
Cut
Cut shall mean all excavated material from the road prism including side or open drains.
Cut to Fill
The process of optimising road construction practice whereby all suitable excavated materials from the
road prism or open drains is used for fill needed to construct nearby embankments.
Cutting
That portion of the road prism from where material is excavated to subgrade or road bed level.
Deflector
Deflector is the device used to deflect a tendon alignment within a structural element.
Delineation Barrier
A barrier used to define hazards and guide traffic through the work site.
Delineator
This is a small retro-reflector(s) or panel(s) of retro-reflective sheeting that is attached to guideposts,
or in the case of traffic barriers to a mounting plate, to provide a coherent pattern of delineation of the
edges of the carriageway as an aid to night driving.
Departure Terminal
A departure terminal is a safety barrier system of a type which is used only at the departure end of the
barrier system with respect to the direction of flow of traffic.
Detour
A detour is a diversion of traffic on existing roadways because of obstruction to the existing roadway
and is required to facilitate safe construction of works.
Ditch
The general term for any longitudinal open excavation or natural channel with the function of surface
water drainage.

Duct
Duct is the void formed to house the tendon (s) and may be formed by coring, or by using sheaths or
by way of extractable cores.
Durability
The ability of a material to withstand wear and tear, breakdown, decay, disintegration and/or
decomposition.
Drawings
The Drawings which show the location, character and dimensions of the prescribed work, including
layouts, profiles, cross-sections and other details.
Earthworks
The excavation of material from cuttings and/or the construction of embankments.
Embankment
That portion of the road prism composed of approved fill material, which lies above the original ground
and is bounded by the side slopes, described in the Contract, extending downwards and outwards
from the outer shoulder breakpoints and on which the pavement is constructed.
Equipment
All machinery, together with the necessary supplies for upkeep and maintenance, and also all tools
and apparatus necessary for the proper construction and acceptable completion of the Works.
Excavation
To remove soil, earth and rocks by digging.
False work
Support for concrete formwork.
Fill
Material which is used for the construction of embankments.
Filler
Processed or naturally occurring material passing the 75 micron sieve which is principally used to
improve the combined Aggregate grading and thus reduce the air voids content of bituminous
mixtures.
Fine Aggregate
Fine Aggregate is crushed or naturally occurring material passing the 4.75 mm sieve.
Fineness Modulus
Fineness Modulus (FM) is an index of the fineness of an aggregate. The higher the Fineness
Modulus, the coarser the aggregate. Different aggregate gradings may have the same Fineness
Modulus. The Fineness Modulus of fine aggregate is useful in estimating proportions of fine and
coarse aggregates in concrete mixtures.
Flexible Guide Post

A post that deflects when impacted by a vehicle and then returns to the vertical position without
maintenance intervention.
Footway
An area normally adjacent to the carriageway provided for the use by pedestrians.
Formation level
The level of the interface between the top of the subgrade layers and the bottom of the pavement
layers and shoulders.
Formwork
Temporary boarding or sheeting erected to contain concrete during placing, compacting and initial
hardening.
Furrow Open Drain/Ditch

A longitudinal drain or bank outside the road prism for diverting water that would otherwise flow onto
the road prism.
Gabions
Gabions consist of woven steel mesh boxes or mattresses filled with stone.
Grade Line
The grade line is a reference line in the Drawings of the longitudinal sections of the road indicating at
regular intervals the elevations according to which the road is to be constructed. The grade line may
refer to the level of the completed road, base or any other layer and may indicate the elevations either
along the carriageway centreline or along any designated position on the road cross-section.
Grading Modulus (GM)

The cumulative percentages by mass of material in a representative sample of aggregate, gravel or
soil retained on the 2.00mm, 0.425 mm and 0.075 mm sieves, divided by 100.
Gravel
Gravel is naturally occurring, rounded, granular material with a particle size of from 2mm to 60mm. (It
does not apply to Gravel Wearing Courses).
Grout Check
A recess formed at concrete construction joints, which may be filled with grout; to mask, and ensure a
straight line to, the joint.
Guide Posts
Guide posts are used to mark the edge of the road carriageway to assist road users by indicating the
alignment of the road ahead, especially at horizontal and vertical curves; and, under some
circumstances, by providing a gauge with which to assess the available sight distance.
Hard Material
Hard Material is defined in Clause 4204.
Haul Road
A portion of the haul route which consists of any public road excluding the road under the contract.
Highway
A general term denoting a public way for purposes of vehicular travel, including the entire area within
the Right-of-Way.
Inlet and Outlet Drainage Channels

Channels leading into or discharging from culverts, storm-water drains and minor bridges.
Inspector
The authorised representative of the Engineer/Supervisor/Employer’s Representative assigned to
make detailed inspections of materials or contract performance.
Interceptor Ditch or Open Drain

A drainage structure designed to divert surface or ground water away from a road or other structure.

Kerb
A concrete or stone structure abutting the edge of a sealed carriageway. It has an up-stand and forms
the separation between the carriageway and footway, verge or traffic island. Its purpose is for
pedestrian safety, to contain movement of the flexible carriageway materials and to assist in
channelling surface water to drainage structures.
Key Personnel
Qualified permanent and contract employees of the Contractor and Sub-Contractors including
contracts managers, site agents, materials and survey technicians, supervisors, trainers, foremen,
artisans, skilled plant operators and the like.
Kicker
A concrete plinth at least 70 mm high above the concrete floor, forming the start of a concrete wall or
column.
Lane
Part of a travelled way intended for a single stream of traffic in one direction, which has normally been
demarcated as such by road markings.
Lateral Distance (for road signs)

The distance from the edge of a sign blade to the centre of the edge line of a roadway, kerb face or
other measurement point designated on a sign inventory form.
Leading Terminal
The approach end of a safety barrier system with respect to the direction of flow of traffic.
Levelling Course(s)
One or more layers of asphalt or granular material, of varying thickness, which are applied to improve
the regularity of an existing road surface.
Lot
A sizable portion of work or quantity of material which is assessed as a unit for the purpose of quality
control and selected to represent material or work produced by essentially the same process and
materials.
Low Volume Roads

Roads designed to the standards of the prevailing edition of the ERA Low Volume Roads Design
Manual and carrying up to about 300 vehicles per day and less than about 1 million equivalent
standard axles over their design life.
Manufacturer’s Recommendations
The methods and procedures for installation of components, systems and devices
Masonry
Stone, block and brick work constructed with interlocking elements; generally mortared, but can be
constructed without mortar.
Materials
Any substance specified for use in the construction of the project and its appurtenances.
Mechanical Stabilisation
The process of mixing or blending soils of two or more gradations to obtain a material of improved
quality, meeting the required specification.
Median
The area between the two carriageways of a dual carriageway road.

Median Drain
A longitudinal drain-situated in the median of a dual carriageway road.
Method of Measurement
The method by which measurement for payment items will be ascertained for individual work items as
collectively defined in Series 0000 and each relevant Division of the Specification under the Clause for
“Measurement and Payment”.
Milling
Excavating and removing a layer of material exceeding 10 mm in thickness from an existing pavement
by means of an approved milling machine. Milling is normally used only in asphalt and cemented
layers.
Mitre Drain/Mitre Bank

A Mitre Drain is a drain constructed at an angle to the centreline of the road to divert water from the
side drains. Mitre drains will include mitre banks placed across side drains.
Modified AASHTO compaction

This refers to the compaction of a soil or gravel material to determine the density and moisture content
relationship using AASHTO method T-180 (ie compaction in a 150mm diameter mould in 5 layers
using a 4.5 kg hammer). This is also called the modified Proctor method and is comparable to the BS
heavy compaction of BS 1377.
Modified Binder – Homogenous

A blend of polymer and bitumen where two distinct phases cannot be detected on a microscopic level;
or where two phases are interwoven to such an extent that the material behaves as a single-phase
material. Examples of homogenous binders are Ethylene Vinyl Acetate (EVA), Styrene Butadiene
Rubber (SBR) and Styrene Butadiene Styrene (SBS) polymer modified binders
Modified Binder – Non-homogenous

Binders that show two distinct, detectable phases; and where there will be localised differences in
properties depending at what stage a test is performed. Bitumen-rubber falls into this category as it
consists of rubber crumbs partially dissolved in a bitumen matrix.
Mortar
A mixture of fine aggregate, cement and/or hydrated lime usually in predetermined proportions, with
water, to create a fine grained cementitious material suitable for the bedding of bricks, blocks and
masonry.
Multi-panel Sign
A sign with a blade manufactured from more than one sheet of aluminium but erected as one section.
Multi-section Signs
A sign with a large blade manufactured from more than one section allowing field-bolting together.
Individual sections may be of single or multi-panel construction.
Obstruction
An obstruction is any works, or otherwise, on or adjacent to an existing carriageway that requires
modification to the existing traffic control arrangements.
Open Drain
The general term for any longitudinal open excavation or natural channel with the function of surface
water drainage.
Optimum Moisture Content for Compaction

The moisture content of a soil calculated on the basis of dry weight of soil at which the soil can be
compacted to the approximate maximum density under a specified standard method of compaction.

Overburden
Overburden is unsuitable material which overlies suitable material within a borrow pit or quarry.
Overhaul
Overhaul is the distance in excess of any free-haul distance. In these specifications, work performed in
haulage of material shall not be paid separately and the cost thereof is deemed to be included in other
rates.
Overlay
An additional pavement layer applied on top of an existing road for strengthening the pavement and/or
for improving the riding quality.
Parking Lane
An auxiliary lane adjoining the travelled way for the purpose of vehicular parking.
Particular Specifications (or Project Specifications)

The specifications relating to a specific project, which form part of the contract documents for such
project, and which contain supplementary and/or amending specifications to the standard
specifications.
Pavement
A multi-layered horizontal structure which is constructed for the purpose of carrying traffic.
Pavement Layers
The layers of different materials, which comprise the pavement structure.
Pavement Markers
Any kind of device or material that is used on a road surface in order to convey official information.
They can also be applied in other facilities used by vehicles to mark parking spaces or designate
areas for other uses.
Pavement Markings
Markings on the wearing surface of a road pavement such as lines, arrows, bicycle symbols, and
words such as "only" and "school”.
Pavement Planing
Planing of an existing road surface by the removal of a layer of material by means of a milling machine
or other equipment.
Pioneer Layer
An initial layer constructed over a weak roadbed where selected material is used to provide a stable
platform for the construction of subsequent layers.
Pre-Stress
Pre-stress is the stress induced in concrete by tensioned tendons.
Pre-Stressed Concrete
Pre-stressed concrete is structural concrete in which effective internal stresses are induced by means
of tensioned tendons.
Pre-Stressing
Pre-stressing is the inducement of compressive stress into a structural concrete element either by pre-
tensioning or post-tensioning tendons comprising cables, wires or bars incorporated into the element.
Pre-Tensioned Concrete
Pre-tensioned concrete is pre-stressed concrete where the tendon is tensioned before the concrete
has been cast.
Project Liaison Committee (PLC)

The primary mechanism for establishing and maintaining communication with the local authorities and
the community affected by any particular project with the key role of monitoring the overall impact of
the project on the affected community.
Post-Tensioned Concrete
Post-tensioned concrete is pre-stressed concrete where the tendon is tensioned after the concrete has
hardened.
Prime Coat
A bituminous treatment applied to the surface of a newly constructed unbound or chemically stabilised
(lime or cement) road base prior to the construction of a bituminous layer or surface treatment.
Project Specifications
See Particular Specifications above.
Public Utilities
Organisations providing public infrastructure or services (eg telephone, power, water, or sewerage
services).
Pull-In
Pull-in is the elastic shortening of the tendon caused by relative movement between the Anchorage or
coupler components on account of seating and gripping action during or immediately after transfer.
Quality Control
Procedures, and/or testing, carried out prior to, or during, the construction of the Works for the
purpose of ensuring compliance with the requirements of the Specification.
Quarry
An area within designated boundaries, approved for the purpose of obtaining rock.
Recycling
The processing of salvaged material in a plant for reuse.
Rehabilitation
Work undertaken to significantly extend service life and improve the condition or riding comfort of an
existing road.
Reinforcement for Asphalt

A cloth or grid of synthetic material placed underneath or between asphalt layers for strengthening the
asphalt.
Release
Release is the specified elastic shortening of the tendon at the Anchorage achieved before or during
transfer.
Retexturing
Treatment of an existing road surface to restore the texture to a specified depth of texture or skid
resistance.
Retro-reflective Raised Pavement Marker

These markers include a lens or sheeting that enhances their visibility by reflecting automotive
headlights. Some other names for specific types of raised pavement markers include Bott’s dots,
delineators, cat’s eyes, road studs, or road turtles. Sometimes they are simply referred to as reflectors.
Retro-reflectivity of Road Signs

Retro-reflectivity is light reflected from a source to a surface and returned to its original source. For
traffic signs and vehicle operators, the light source is a vehicle’s headlights, where the light is sent to

the traffic sign face and then returned to the vehicle operator. Traffic signs are manufactured with
retroreflective sheeting so that the traffic sign is visible at night. Reflective sign faces are manufactured
with glass beads or prismatic reflectors imbedded in the sheeting so that the face reflects light,
therefore making the sign appear more bright and visible to the vehicle operator.
Right-of-Way
The land secured and reserved by the Roads Authority for the construction and maintenance of a
road.
Rip-rap
Un-bonded stone provided to protect the surfaces of slopes and the beds of watercourses from
erosion and scour.
Road Base
A layer of material of defined thickness and width constructed on top of the sub-base, or in the
absence thereof, the subgrade. A road base may extend beyond the carriageway.
Roadbed
The natural in-situ material on which the fill, or in the absence of fill, any capping, selected subgrade or
pavement layers, are to be constructed.
Roadbed Material
The material below the road bed level extending to such depth as affects the support of the
embankment structures or capping/selected sub-grade layers.
Road Prism
The cross sectional area bounded by the original ground level and the sides of slopes in cuttings and
embankments.
Road Safety Barrier

These barriers are sometimes called “crash barriers”, or “Armco” (barriers) and are designed to keep
vehicles within their roadway; and to prevent vehicles from colliding with dangerous obstacles such as
boulders, buildings, walls or large storm drains. Safety barriers are also installed at the road side to
prevent errant vehicles from traversing steep (non-recoverable) slopes or entering deep water.
Road Safety Barrier System

Road safety barriers systems are designed to provide a high level of road safety by containing and
redirecting errant vehicles and thereby preventing them from leaving the road. A range of barrier
systems are available for use in both permanent and temporary situations.
Roadside
The portion of the highway outside the roadway.
Road Reserve
The limit of the road reserve shall be as shown on the Drawings and shall generally include the metric
limits of the earthworks for cut-off and toe drains; for junctions; and for culverts and watercourses; plus
working areas on either side of the road.
Roadway
The roadway comprises the carriageway, shoulders and median.
Rock
A mass of hard mineral material which, when excavated, requires the use of explosives, sawing or
splitting by mechanical means.

Roller Passes
Unless otherwise specified in the Standard Specifications or the Particular Specifications, an area will
be taken to have received one roller pass when a roller has passed over such area once. Additional
passes made only as a result of nominal overlapping so as to ensure full coverage shall not be taken
into account.
Sand Equivalent Value (SEV)

This test method (ASTM D2419) provides a rapid field method for determining changes in the quality
of aggregates during production or placement. It assigns an empirical value to the relative amount, of
fineness and character of claylike material present in the test specimen.
Scabbling
The use of a hand-held or self-supporting percussion machine to remove the surface of hardened
concrete without damaging the structure.
Scarify
Loosen and break-up soil or existing pavement layers by means of a machine fitted with tines.
Screed
A layer of fine-graded asphalt or slurry placed to fill in slacks in existing seals and to improve the riding
quality of the road.
Seal
The application of one or more layers of bituminous binder with or without layers of crushed stone,
sand or slurry in successive layers on the carriageway, shoulders or on any other compacted layer on
which movement of traffic takes place.
Selected Layer
The lower layer or layers of the pavement which is constructed directly onto the fill or in some cases
the roadbed. It may include roadbed material compacted in situ. (Also see definition for capping
layers/selected subgrade)
Services
Cables, pipes or other structures to provide, inter alia, conduits for electricity, telephone and telegraph
connections, water, sewage, etc.
Sheath
Sheath is the tube or casing enclosing the tendon and which temporarily or permanently allows a
relative movement between the tendon and the surrounding concrete.
Shoulder
(a) When referring to this as a surface: The area between the outside edge of the travelled way and
the shoulder breakpoint.
(b) When referring to this as a pavement layer: The upper pavement layer lying between the outside
edge of the base and the shoulder breakpoint.
Shoulder Breakpoint
The point on a road cross section at which the extended flat planes of the surface of the shoulder and
the outside slope of the fill and pavement intersect.
Side Drain
A longitudinal drain offset from, and parallel to, the carriageway.
Side Fill
Side fill is either surplus or additional fill which is used to extend and flatten the slope of an
embankment and which is often compacted to a lower standard than the former.

Sidewalk
A pedestrian walk-way along the side of a road. (In colloquial English sometimes called a pavement
and should not be confused with the road pavement)
Site
The area of land within which the Contractor will construct the permanent works which shall also
include areas set aside for camps, temporary works, pre-cast yards, borrow areas, quarries and
diversions.
Skew or Skew Angle

The acute angle formed by the intersection of a line normal to the centreline of the roadway with a line
parallel to the centreline of bents, piers or abutments of a bridge, or in the case of a culvert, with the
centreline of the culvert barrels.
Slope
Unless otherwise stated, slope is given in terms of the ratio of the vertical difference in elevation
between any two points and the horizontal distance between them. The ratio may also be expressed
as a percentage.
Soft Material
Soft Material is defined in sub-clause 4204(a).
Spalls
Chipped or splintered fragments of stone or concrete.
Specifications
The general term comprising all the directions, provisions and requirements contained within the
prevailing version of the "ERA, Standard Technical Specification and Methods of Measurement for
Roadworks", together with such as may be added or adopted as supplemental specifications or as
Particular Specifications, and all documents of any description, including notes on plans, pertaining to
the method and manner of performing the work or to the quantities and qualities of materials to be
furnished under the contract.
Spoil (Material)
Surplus or unsuitable material originating from construction operations.
Stabilisation
Stabilisation refers to the various methods employed for modifying the properties of a soil to improve
its engineering performance
Also see definitions for “Bitumen Stabilisation”, “Chemically Stabilised Materials” and “Mechanical
Stabilisation”.
Standard Drawings
Drawings approved for repetitive use showing details to be used where appropriate.
Stone Pitching
A single course of stones placed on edge with spalls rammed into the spaces between the stones.
Structures
Bridges, culverts, catch basins, drop inlets, manholes, retaining walls, cribbing, end walls, buildings,
sewers, service pipes, under-drains, foundation drains, and other miscellaneous items, which may be
encountered in the work, and which are not classified herein.

Sub-Base
The pavement layer of material of specified dimensions on top of the subgrade and below the road
base.
Sub-Contractor
Any individual, firm or corporation to whom the Contractor sublets any part of the contract.
Subgrade
The surface upon which the pavement structure and shoulders are constructed.
Sub-soil
The layer or bed of earth beneath the topsoil.
Sub-soil (Sub-Surface) Drain

A covered drain constructed to intercept and remove subsoil water. It includes all pipes and filter
material in the drain.
Substructure
All of that part of the structure below the bridge seats or below the spring lines of concrete arches.
Back walls and wing walls of abutments shall be considered as parts of the substructure.
Superstructure
All parts of a structure above and including the bearing of simple and continuous bridge spans,
skewbacks of arches, decks slab bridges etc.
Surface Dressing
The sealing or resealing of the surface of the carriageway or shoulders by means of one or more
successive applications of bituminous binder and chippings.
Surface (Wearing) course

The uppermost layer of a pavement structure designed to accommodate traffic loads, provide
resistance to skidding and traffic abrasion, and to protect the underlying pavement layers from water
ingress.
Tack Coat
A bituminous treatment applied to the surface of an existing bituminous layer or a cement concrete
pavement prior to the construction of a new bituminous layer.
Temporary Works
All works required for the completion of the Works contract but not incorporated into the permanent
Works (eg for purposes of temporary support, access, safety, traffic diversion, etc.).
Tendon
Tendon is the pre-stressing steel consisting of the bar, wire or strand individually placed, or of bars,
wires or strands placed in a duct, all of which are tensioned to impart pre-stress to a concrete member.
Tensioning
Tensioning is the action of inducing and regulating the force in a tendon by means of tensioning and
measuring equipment.
Texture Treatment
Treatment of an existing road surface to obtain a uniform texture.
Topsoil
A surface layer of soil, which contains organic matter and is capable of supporting the growth of
vegetation. Topsoil falls within the definition of “Spoil”.
Traffic
Vehicles, pedestrians and animals travelling along a route.
Traffic Control Device

Traffic control devices are markers, signs and signal devices used to inform, guide and control traffic,
including pedestrians, motor vehicle drivers and bicyclists. These devices are usually placed adjacent,
over or along the roads, traffic facilities and other public areas that require traffic control
Traffic Lane
Part of a carriageway intended for a single stream of traffic in one direction, which has normally been
demarcated as such by road markings.
Transfer
Transfer in the case of post-tensioned concrete is the action of transferring the tensioning force from
the tensioning equipment (jack) to the Anchorage.
Transfer in the case of pre-tensioned concrete is the action of transferring the force in the tensioned
tendon(s) to the concrete.
Transmission length
Transmission length is the tendon length required to transmit via bond stresses the full force in the
tendon to the concrete.
Travelled Way
That portion of the carriageway, which includes the various, traffic lanes and auxiliary lanes but
excludes the shoulders.
Unbound Material
Naturally occurring or processed material which is not bound together by the addition of a binder such
as cement, lime or bitumen.
Unsuitable Material
Unsuitable material is defined in sub-clause 4103 (a).
Utility Lines
All infrastructure such as telephone, power, water and sewer lines laid for public services.
Verge
The area between the outer edge of the road prism and the boundary of the road reserve.
Wheel Track
The path followed by the wheel of a vehicle during normal riding movements. The wheel tracks cover
approximately the outer metre width on both sides of a traffic lane.
Windrow
A build-up or row of material on the edge of newly graded earthworks and/or pavement layers for
surfaced and unsurfaced roads.
Work Area
The specific area where the work is being done.
Working Drawings
Stress sheets, shop drawings, erection plans, false work plans, cofferdam plans, bending diagrams for
reinforcing steel, or any other supplementary plans or similar data which the Contractor is required to
submit to the Engineer for approval.
Workforce
All employees of the Contractor and Sub-Contractors on the Site that are not considered Key
Personnel (as defined above).

Work Site
An area the includes the Work Area(s) and any additional length of road required for advanced
signing, tapers, side-tracks or other areas required for associated purposes.
Figure 1102/1: Terms and Definitions for Road Cross Section Elements
Figure 1102/2: Terms and Definitions for Flexible Pavement Structure

Figure 1102/3: Terms and Definitions for Rigid Pavement Structure
Figure 1102/4: Terms and Definitions for Gravel Road Cross-section Elements

1103 Abbreviations
AASHTO/AASHO American Association of State Highway and Transportation Officials or
American Association of State Highway Officials
AC Asphalt Concrete
ACI American Concrete Institute
ACV Aggregate Crushing Value
AIV Aggregate Impact Value
ALD Average Least Dimension
ANSI American National Standards Institute (previously, American Standards

Association, ASA)
ASTM American Society for Testing Materials
BA Bitumen Affinity
BS British Standards
CBR Californian Bearing Ratio
CC Conditions of Contract
DM Durability Mill
DMI Durability Mill Index
EC Electrical Conductivity
FHWA Federal Highways Authority
FI Flakiness Index
FM Fineness Modulus
FMC Field Moisture Content
GM Grading Modulus
HMA Hot Mix Asphalt
ICS Initial Consumption of Stabiliser
Ip Plasticity Index (also see PI)
ISO International Organisation of Standardisation
LAA Los Angeles Abrasion value
LL Liquid Limit
LS Linear Shrinkage
MDD Maximum Dry Density
mesa million equivalent standard axles
OMC Optimum Moisture Content
PI Plasticity Index (also see Ip)
PL Plastic Limit
PM Plastic Modulus (Product of PI and % passing 0.425 mm Sieve)

PP Plasticity Product
QCM Quality Control Manual
QCS Quality Control System
RoW Right of Way
SABITA Southern Africa Bitumen Association
SABS South African Bureau of Standards
SANS South African National Standards
SEV Sand Equivalent Value
SI International Standard Unit of Measurements
SG Specific Gravity
SSS Sodium Sulphate Soundness
TS Tensile Strength
UCS Unconfined Compression Strength
UTRC Ultra-Thin Reinforced Concrete
VIM Voids in Mix
VFB Voids Filled with Binder
VMA Voids in Mineral Aggregate
10% FACT 10% Fines Aggregate Crushing Test
The following other symbols, unit of measurement and abbreviations are used:
ha Hectare
kg Kilogram
km Kilometre
L. Sum Lump Sum
m Linear metre
2
m Square metre
3
m Cubic metre
mm Millimetre
No. Number
Prov. Sum Provisional Sum
Veh-mth Vehicle Months
Man-mth Man Months
t Tonne
Month Calendar month

l Litre
MBM Thousand metre board measure
MN Meganewton
MN-m Meganewton-metre
MPa Megapascal
Pa Pascal
% Percentage
°C Degrees Celsius
hr hour

Division 1200: General Requirements and Provisions
1201 Scope
This Division covers matters, which relate to the construction work as a whole. Definitions, phrases or
wording, which would otherwise require repetition in other Divisions of the Specifications, are also
covered by Clauses in this Division.
1202 Workmanship and Quality Control

It is the Contractor's responsibility to produce work, which conforms in quality, quantity and accuracy of
dimensions to the requirements of the Specifications and Drawings. The Contractor must implement
his own quality control system with experienced staff, together with all necessary facilities, to ensure
adequate supervision and positive control of the Works at all times.
If the Engineer has any doubt concerning the quality of any material to be used in the Works, he shall
instruct the Contractor to carry out tests to prove the quality of material before it is used in the Works.
The results of tests, which are carried out by the Contractor, shall be submitted to the Engineer on
request.
The Contractor shall provide, maintain and staff the site material laboratory at his own cost throughout
the Contract, to the satisfaction of the Engineer. The Contractor will not be allowed to commence
permanent work until the Contractor’s laboratory and staffs have been approved and the laboratory
building completed and furnished with all equipment to the Engineer’s satisfaction.
The cost of all supervision and process control, including, but not restricted to, quality control testing;
subgrade design CBR verification at 500 meters intervals or at designated intervals by the Engineer to
define unsuitable subgrade sections; and construction materials exploration so carried out by the
Contractor, shall be deemed to be included in the rate tendered for the relevant items of work, except
that the cost of certain tests and the provision of certain items of testing and sampling equipment will
be paid for separately as provided for in those sections of the specifications where this applies.
The Contractor shall develop a Quality Control System (QCS) in consultation with and entirely to the
satisfaction of the Engineer and shall be described in a Quality Control Manual (QCM). This shall be
represented in four (4) copies, two (2) to the Employer and two (2) to the Engineer, for review and
comment during the mobilisation period. The Contractor shall modify the QCM if required and submit
copies of the final document for the use of the Employer and the Engineer also in four (4) copies, two
(2) to the Employer and two (2) to the Engineer.
The QCM shall be in a suitable binding so that it can be updated from time to time and shall include
inter alia:
 The Contractors general approach to providing a QCS;

 The quality control organisation with details of staffing and inter-relationships and
responsibilities within the Contractor’s organisation and with the Engineer;
 A detailed description of the request system for checking completed works and for the
inspection of elements when required prior to performing works;
 Methods and frequency of testing for all elements of the works;
 Reporting procedures;
 Procedures for rectifying identified deficiencies;

 Standard Formats proposed for use in the system with a description of how they are to be
used during the project;
 Software proposed for use in maintaining system records and reporting. Where the Contractor
proposes software for use in the system, copies must be provided for the free use of both the
Employer and the Engineer.
The methods of reporting and any standard formats proposed must be compatible with the inputs
required by the Employer’s record system.
The Contractor’s attention is drawn to the provisions of the various Divisions of the Specifications
regarding the minimum frequency of testing that will be required to undertake process control. The
Contractor shall at his own discretion increase this frequency where necessary to ensure adequate
control.
The Contractor shall submit to the Engineer for examination and approval as necessary, the results of
all relevant tests, measurements and levels indicating compliance with the Specifications on
completion of every part of the work.
The Contractor shall supply the Engineer with certificates of compliance obtained from the suppliers of
products such as cement, bitumen, steel reinforcement, gabion boxes and other fabricated materials
and equipment used in the Works. Should the Contractor wish to change supplier, certificates from the
new supplier must be approved by the Engineer.
The Contractor shall provide, maintain and staff his own site material laboratory at his own expense
throughout the Contract, to the satisfaction of the Engineer. The Contractor will not be allowed to
commence permanent work until the Contractor’s laboratory and staffs have been approved and the
laboratory building completed and furnished with all equipment to the Engineer’s satisfaction.
The schedule of testing in the QCM shall take cognizance of the key stages of construction so that
tests are timely, informative, relevant and do not cause unnecessary delay. The purpose of the QCM is
for the Contractor to provide records that demonstrate to the Engineer, in the fullness of time, that all
the requirements of this Specification have been met.
In preparing the project QCM, the Contractor shall also take into consideration that:
 No operation shall be carried out without full and complete written notice having been given to
the Engineer by the Contractor sufficiently in advance of the time of the operation to enable
the Engineer to make such arrangements as he may deem necessary for its inspection,
testing and checking.
 The Contractor shall give the Engineer not less than 24-hours’ notice in writing of his intention
to set out or give levels for any part of the Works in order that arrangements may be made for
checking and testing. No specific pay items are provided as compensation for the above
obligations, including the provision of all samples delivered to the Engineer, for which
compensation shall be included in the contract rates of the Contractor for the various items of
work to which these obligations apply.
1203 Approval of Completed Works

Unless otherwise instructed by the Engineer, the Contractor shall submit a request and obtain
approval for each completed element of the Works and shall not proceed with subsequent elements
until approval is granted. The Contractor shall give a minimum of 24 hours’ notice in writing to the
Engineer to allow any inspection and testing to be carried out. Any approval given by the Engineer
shall not relieve the Contractor of any of his obligations under the Contract.

The Contractor shall submit to the Engineer the results of all relevant tests, measurements, and levels
indicating compliance with the Specification on completion of every part of the work.
1204 Setting Out of Work and Protection of Survey Monuments

The Contractor's attention is drawn to the requirements of the Conditions of Contract regarding setting
out of the Works.
The Contractor shall check for the accuracy or existence of original marks, lines and levels of
reference not less than one month prior to commencing works in any section, to allow sufficient time
for reinstatement of markings, and checking of lines and levels. Any discrepancies encountered shall
be reported at once to the Engineer, for instruction and co-ordination. The Contractor shall be deemed
to have allowed in his tender price for checking and reinstatement of original markings.
A survey monument, which has been disturbed, shall not be used unless its true position and level has
been re-established and the new values have been verified by the Engineer.
The Contractor shall establish working Benchmarks tied to the reference benchmark in the area soon
after taking possession of the site. The working benchmarks shall be established by the Contractor at
the rate of four per km and also at or near all cross-drainage structures, bridges, water crossings and
road intersections, to the approval of the Engineer.
The carriageway centreline shall be accurately established by the Contractor. It shall be accurately
referenced in a manner satisfactory to the Engineer, with marker pegs and chainage boards and a
schedule of reference dimensions shall be prepared and supplied by the Contractor to the Engineer.
These markers shall be maintained until completion of the work.
Where a survey monument is likely to be disturbed during construction operations, the Contractor shall
establish suitable reference survey monuments at locations where they will not be disturbed during
construction. Survey monuments shall be established on a steel pin set in concrete or another less
permanent manner approved by the Engineer. No survey monument shall be covered over, disturbed
or destroyed before accurate reference survey monuments have been established and details of the
position and levels of such survey monuments have been submitted to the Engineer and approved by
him. The Contractor's reference survey monuments shall be of at least the same quality and durability
as the existing survey monuments.
The Contractor shall submit to the Engineer the method of setting out he proposes to employ. The
Engineer may at any time request the Contractor to submit proof that his setting out has been
satisfactorily checked.
If any trigonometry survey monuments, benchmarks or other land survey marks are disturbed or
destroyed during construction they shall be replaced by the Contractor so as not to disrupt the
Contractor’s Programme. Special care shall be exercised during construction not to damage, displace
or disturb property and trigonometrical survey monuments.
Accurate control of line and level shall be provided by the Contractor at all stages of construction. In
respect of the road itself, control shall be at 20m intervals, or such closer intervals as may be directed
on horizontal and vertical curves. Wherever necessary, but particularly on completion of the subgrade
and the base, the Contractor shall re-establish stake line pegs at sufficiently close intervals to
determine accurately the edges of the base, surfacing and other road elements permanently exposed
to the eye.
The Contractor shall place slope stakes and batter boards at the toe of the embankment slope and at
the top of cut slopes, when these points are more than 2m vertically above or below the finished road

level. Centreline stakes for culverts and other structures shall be places as required or as directed by
the Engineer. The Contractor shall put in place, all templates, additional stakes and markers
necessary for control and guidance of his construction operations and shall be solely responsible for
maintaining the stakes.
1205 Standards
(a) Equivalency of Standards and Codes

American, British, South African and Ethiopian standards are used in this Technical Specification. In
the absence of any definite provisions in the Specification on any particular issue, reference may be
made to the latest, relevant Ethiopian Standards, AASHTO, ASTM, BS or SANS/SABS standards and
codes.
Where such standards and codes are national, or relate to a particular country or region, other
authoritative standards which ensure an equal or higher quality than the standards and codes
specified will be accepted subject to the Engineer’s prior review and written approval. Differences
between standards specified and the proposed alternative standards must be fully described in writing
by the Contractor and submitted to the Engineer at least 28 days prior to the date when the Contractor
desires the Engineer’s approval. In the event that the Engineer determines that such proposed
deviations do not ensure equal or higher quality, the Contractor shall comply with the standards set
forth in this document.
The construction and completion of the Works and relevant tests shall conform to sound engineering
practice and, in case of any dispute arising out of the interpretation of the above, the decision of the
Engineer shall be final and binding on the Contractor.
(b) Compliance with Specified Standards and Codes

All materials and workmanship shall comply in all respects with the relevant requirements of the
specified standards and codes.
Wherever reference is made to specific standards and codes to be met by goods and materials to be
furnished and work performed or tested, the provisions of the latest current edition or revision of the
relevant standards and codes in effect shall apply. Latest editions shall in this context be as at 28
days before the date for submission of tenders. If, after the date of issue of the Tender, there is an
amendment to a standard or code, the Engineer will determine whether the amendment is to apply.
(c) Supply of Standards and Codes

The Contractor shall, within six (6) weeks of the receipt of the Notice to Commence, provide the
Engineer with two (2) copies of the latest edition of all codes of practice and standards referred to in
the Technical Specification.
(d) Trade Names

Where trade names or Manufacturers’ catalogue reference numbers are mentioned in the Technical
Specifications or the Bill of Quantities, they are intended only to serve as a guide to the type of article
or material required. The Contractor may use any article or material similar and equal to those
specified subject to approval of the Engineer. The Contractor shall provide identifying details of
proposed alternative products in the Bill of Quantities.
(e) Materials and Manufactured Articles

Before placing any order for materials and manufactured articles for incorporation in the Works or to
be supplied under the Contract, the Contractor shall submit to the Engineer the names of the firms
from whom such materials and manufactured articles shall be obtained; giving for each firm a
description of the materials and manufactured articles to be supplied, their origin, the Manufacturer’s
specification, quality, weight, strength and any other relevant details. The Contractor shall deposit with
the Engineer samples of such materials and manufactured articles when requested and, where
appropriate, Manufacturer’s certificates of recent tests carried out on similar materials and
manufactured articles. The Contractor shall provide the Engineer with copies of all orders for the
supply of materials and manufactured articles required in connection with the Contract as the Engineer
may require. The Contractor shall also supply all relevant manuals.
1206 Protection of the Works and Requirements to be met before Construction

of New Work on Top of Completed Work is Commenced
The General Obligation of the Contractor in terms of the General Conditions of the Contract shall inter
alia include the following:
(a) Temporary Drainage Works

The provision of temporary drainage works such as drains, open channels, banks, etc. and the
furnishing and operating of temporary pumps and such other equipment as may be necessary to
adequately protect, drain and dewater the works and temporary works. This will be in addition to any
permanent drainage works specifically paid for separately.
(b) Borrow Pit Material

Care shall be exercised not to allow material in borrow pits to become excessively wet, to keep all
completed layers properly drained, not to cause dumps of material on completed layer work to inhibit
surface drainage or to form wet spots under and around dumps, and to protect all parts of the work
against erosion by floods and rain.
Material shall not be spread on a layer that is so wet as to result in the danger of damage being
caused to the layer during compaction of a subsequent layer or when opened to traffic.
When material is spread out on the road, it shall, during wet periods, be given a good cross-fall, and a
light compaction on the surface with a steel-wheeled roller, in order to facilitate run-off during rainy
weather.
(c) Fill and Cut Slope Repair

Fill and cut slopes shall be promptly repaired whenever damaged by surface water. Where erosion
occurs on high fill, the slopes shall be repaired by cutting back to form benches and compacting the
back fill mechanically to the specified controlled densities, using suitable small equipment.
(d) Water Ingress at Excavations

Excavations for pipe drains, culverts, sewer drains, water mains, manholes, service ducts, and similar
structures shall be adequately protected against the possible ingress of water during rainstorms.
(e) Protection of Layer Work

All completed layer work shall be protected and maintained until the following layer is applied.
Maintenance shall include immediate repairs to any damage or defects, which may occur and shall be
repeated as often as is necessary to keep the layer continuously intact and in a good condition.
(f) Damage to Completed Layers

Before any completed layer is primed or a succeeding layer constructed thereon, any damage to the
completed layer shall be repaired so that after repair or reconstruction if necessary, it will conform in all
respects to the requirements specified for that layer. All repair work other than minor surface damage
repairs shall be submitted to the Engineer for inspection before covering up.
Except as otherwise specified, the Contractor shall be responsible for dealing with, and remedying,
damages caused by water on the Site whether from existing drainage systems, water courses,
underground springs, precipitation or any other source or cause. In discharging and diverting water,
the Contractor shall avoid flooding or damaging other works or services, causing erosion and/or
polluting water courses. In addition, the Contractor shall take appropriate steps to prevent soil erosion
and keep the site and borrow areas free from flooding.
The previously constructed layer shall be thoroughly cleaned of all foreign material before construction
of a succeeding layer or application of a prime coat, surfacing or surface treatment. In the case of all
bituminous work in particular, the completed layer shall be thoroughly broomed and all dung, clay,
mud, and other deleterious material removed. Where necessary, the surface shall be sprayed with
water before, during, and after brooming to remove all foreign material.
1207 Existing Public Utilities

The Contractor, before starting the Works, shall inquire and obtain the necessary information from the
authorities concerned with the utility lines such as water pipe lines, telephone lines, electricity lines,
etc., regarding the location and exact position of such lines, in order to take the proper measures for
avoiding any damage to such utility lines during the execution of the construction works.
The Contractor shall carry out the necessary investigations to identify the location of all existing public
utilities within the RoW and provide accurate records of such to the Engineer prior to commencement
of the Works.
The Contractor’s investigations shall include but not be limited to:
 Obtaining copies of the services plans from local authorities and service authorities;
 The excavation and backfilling in accordance with the specifications of trial pits to locate
services; and
 The preparation of service Drawings to a suitable scale or scales showing the location of all
services at Site.
The Contractor shall appoint a services Engineer to carry out these duties, liaise with the authorities
and the public and maintain and report on services records.
The Contractor shall notify the Engineer, and provide accurate records, of any public utilities
encountered during the execution of the Works. He shall take all necessary steps to prevent damage
to and safeguard any such services. These records shall be kept on forms approved by the Engineer.
The Contractor shall co-operate with the public utility authorities in the removal and relocation of any
underground or overhead services or facilities so as to safeguard and minimise disruption to the
services. In the event of a utility service being interrupted as a result of damage caused by the
Contractor, the Contractor shall promptly notify the authority concerned and be responsible for the cost
of any repairs that are required to restore the services.
The project may include certain work relating to the moving of existing services that may be affected
by the construction of the works and their reinstatement.
The Contractor shall take all reasonable precautions not to cause damage to the existing services
during construction. All pipes, cables, conduits or other services of any nature whatsoever damaged
as a result of the Contractor’s operations shall be repaired and reinstated forthwith by the Contractor
or by the Authority concerned, all at the expense of the Contractor and to the satisfaction of the
Engineer.
Whenever services are encountered which interfere with the execution of the works and which need to
be relocated, the Contractor shall immediately notify to the Engineer. The Engineer will arrange the
relocation or removal of utilities such as telephone and electricity lines, water and/or sewerage pipes,
taps etc. with the relevant authorities and shall make payment for any such compensation associated
therewith. Up to three (3) months will be required for the relocation or removal of these services in
rural areas and up to four (4) months in urban areas, unless otherwise specified in the Particular
Specifications.
It shall be clearly understood that, in certain instances, existing services can be relocated only after
the Contractor has advanced sufficiently on or has completed certain sections of the works or certain
structures.
In the event the Engineer determines that a period of service interruption is unreasonably long, due to
the need for relocation and replacement of service utility lines like water supply and sewerage, then
the Contractor shall provide alternative service lines temporarily for the community use.
1208 Remedial Work

When any part of the works or any plant or material is found upon examination by the Engineer not to
conform to the requirements or is at any stage before final acceptance damaged so that it no longer
conforms to the requirements of the specifications, the Engineer may order its complete removal and
replacement, at the Contractor’s expense, with satisfactory work, plant or material or he may permit
the Contractor to apply remedial measures in order to make good any such defects or damage. The
actual remedial measures shall at all times be entirely at the Contractor’s own initiative, risk and cost,
but subject to the Engineer’s approval regarding the details thereof.
Remedial measures shall ensure full compliance with specifications of the final product, shall not
endanger or damage any other part of the Works and shall be carefully controlled.
For the guidance of the Contractor an indication is given below of what would normally be required in
the more common cases of defects or damage, but the Engineer will in no way be bound to approve of
or adhere to the measures given below as the actual remedial measures will be dictated by the
circumstances of each particular case.
(a) Earthworks
Where a cut slope has been over-excavated or undercut, backfilling will not normally be allowed and
the entire slope may have to be re-trimmed to obtain a uniform slope.
Where the floor of a cut has been taken too deep, it will normally require backfilling and re-compaction
with selected gravel in the case of soil or gravel excavation and with crushed stone material or suitably
sized rock in the case of hard excavations. All necessary measures shall be taken to drain away
ground water that may accumulate in backfilled sections.
Excess width of fills will have to be trimmed down.
Where erosion has damaged the surface of cuts or fills the damage shall be made good by backfilling
with suitable material and re-trimming. In more serious cases the slopes may have to be cut back and
backfilled by benching and compaction to the required standard of compaction with suitable small
equipment and then re-trimmed.
Where excavated material has been allowed to spill over the edge of existing slopes, this surplus
material shall be removed and the vegetation of the slope reinstated.

(b) Stabilising
Any sections failing to meet the requirements specified or damaged to the extent that they require
breaking up and re-compaction will have to be re-stabilised with the type and quantity of stabilising
agent ordered by the Engineer. The Engineer may also order that the layer be removed entirely and
replaced with fresh material to be stabilised.
(c) Local defects in pavement layers

Where remedial measures are taken to make good local defects, the length and width of the area to
be repaired by machines shall be such as will be necessary to accommodate the full width of the
machines used and a reasonable length to ensure effective operation.
The depth to which material will have to be removed will depend on the type of material. Gravel will
require breaking up to a depth of at least twice the maximum particle size and crushed stone will
usually require breaking up over its full depth. Asphalt material will normally require removal for its full
depth.
(d) Concrete
Concrete work will normally require the cutting back and complete removal of any weak or
honeycombed sections and making good using special epoxy adhesives to bind fresh concrete to old
concrete. Cracks, when permitted to remain shall be injected with suitable epoxy compounds and test
cores drilled to test the efficiency of the injection process.
1209 Water
The Contractor shall make arrangements for procuring, transporting, storing, distributing and applying
the water needed for construction and other purposes, except where otherwise specified. No direct
payment shall be made for providing water, the cost of which shall be included in the rates tendered
for the various items of work for which water is needed. Only clean water, free from undesirable
concentrations of deleterious salts and other materials shall be used in the construction of the works.
The Engineer must approve all sources of water used.
If required under the Particular Specifications, the Contractor shall submit water analyses carried out
by an acceptable laboratory for all water sources when submitting the source for approval of the
Engineer. Each source accepted for use in the project shall be retested at three-month intervals while
in use or at the request of the Engineer to confirm its continued acceptability for use in the works.
In areas of water scarcity, the Contractor shall refrain from interfering with the existing community
water supply, and shall develop its own water supply sources, or transport it from areas of ample water
resources.
The Contractor shall provide adequate crossing structures for farmers’ traditional irrigation channels
crossing the existing road in order not to interfere with the local farmers' agricultural activities. The
Contractor shall not exploit water sources used for humans/livestock consumption unless the
Contractor, in consultation with the Engineer and Employer, has obtained prior written agreement from
local officials and community representatives who benefit from such water resources.
The Contractor shall not dump any solid and liquid wastes from workshops and camps into streams,
rivers and wetlands.
The Contractor shall not block the natural flow of streams, rivers and wetlands. In case, for
unavoidable reasons, it becomes necessary to block such flows, the Contractor shall undertake this
action in consultation with the Engineer and local officials and community representatives who are
affected from interruption of such water flows.

Rivers with perennial water, river beds and banks shall not be used as a source of quarry materials,
except for river sand and gravel sediments not directly affecting the river flow.
The Contractor shall, to the satisfaction of the Engineer and Employer, be responsible at his own cost,
for cleaning up any deliberate or accidental spillage of waste chemicals or used oils in the water
sources and farmlands owing to the Contractor’s activities. In addition, the Contractor shall be
responsible for any payments related to full compensation to those affected people, including cleaning
or treating the water in accordance with the Environmental Pollution Control, Proclamation No.
300/2002.
There should not be harvesting of fish or other aquatic organisms by the construction Workforce
without the permission of the responsible authority or organisation.
The Contractor shall, with necessary measures taken to satisfy the environmental and safety
requirements as specified by the responsible local authorities and administrative offices, officially hand
over any water sources which have been developed for construction purposes, to the relevant local
Water Resources Development Office or equivalent thereof.
(a) Water Quality Type A

Water quality type A shall comply with the requirements of BS 3148.
(b) Water Quality Type B

Water quality type B shall be free from undesirable concentrations of deleterious salts and other
materials.
1210 Use of Explosives and Demolition

Generally the Contractor will be permitted to use explosives for breaking up rock and hard material
during excavations, for demolishing existing structures, and for such other purposes where it may
normally be required, subject to the following conditions:
 The Engineer shall have the power to prohibit the use of explosives in cases where, in his
opinion, the risk of injury or damage to persons, property or adjoining structures is too high.
Such action by the Engineer shall not entitle the Contractor to any additional payment for
having to resort to other less economical methods of breaking up rock and hard material, or
demolition, unless otherwise provided for in the Bill of Quantities.
 Before any blasting is undertaken the Contractor, together with the Engineer, shall examine
and measure up any buildings, houses or structures in the vicinity of the proposed blasting
and establish and record together with the owner thereof the extent of any cracking or damage
that may exist before commencement of blasting operations. It shall be the responsibility of
the Contractor to make good at his own expense further damage to such houses, buildings or
structures which is a result of the blasting.
 Where there is reasonable danger of damage to power and telephone lines or any other
property the Contractor shall suitably adapt his method of blasting, the size of charges and
use adequate protective measures such as cover blasting in order to limit the risk of damage
as far as possible.
 Only authorised personnel will carry out all charging and detonation of explosives.
 The Engineer shall be advised, in writing, twenty-four (24) hours before each blasting
operation is carried out, unless otherwise agreed with the Engineer.

 The Contractor shall make arrangements at his own cost for the supply, transport, storage and
use of explosives.
 Legal provisions related to the storage, transportation and use of explosives and the
requirements of the relevant authorities shall be strictly complied with.
 All legal documents and permits for acquisition, transportation and storage of the explosives,
and site plan and the selection criteria of the site, should be submitted for the Engineer’s
approval prior to establishment of the storage facility for explosives, and demolitions.
(a) Compliance with Laws and Regulations

The Contractor shall comply with the current Government proclamations, directives, laws and
regulations in respect of transport, storage and use of explosives and radioactive materials.
The Contractor shall keep in his office at the Site copies of proclamations, directives, laws and
regulations applying to the supply, transportation, handling, storage and usage of explosives and shall
supply one copy of each of those documents to the Engineer. The Contractor shall also submit to the
Engineer a copy of any instructions or notices that the Contractor may issue to his staff or workers, or
post about the Site in compliance with such laws or regulations.
The Contractor shall submit to the Engineer details of the explosives that he proposes to use and of
his proposals for their storage on and transportation to the Site.
(b) Personnel Responsible for Blasting

The Contractor shall appoint a responsible and experienced person or persons to order and receive
explosives and to be responsible for all blasting activities. The name(s) and details of experience of
such person(s) shall be submitted to the Engineer for approval. The Contractor shall only employ
properly qualified and experienced personnel, approved by the Engineer in the handling and firing of
all charges.
(c) Directions for use

Explosives shall be used in accordance with the recommendations of BS 5607.
In the use of explosives, the Contractor shall exercise the utmost care not to endanger life or property
and shall obtain any necessary permits from, and comply with the requirements of all authorities
having jurisdiction with the area before any explosives are used. The Contractor shall use explosives
for blasting in connection with the Works only at such times and places and in such a manner as the
Engineer may approve, always provided that such approval shall not relieve the Contractor from his
responsibility for injury, loss, inconvenience and annoyance to persons, damage to the Works and
adjoining or adjacent structures, roads, places and things, consequent on the use of such explosives.
The Contractor shall be entirely liable for any accident that may occur and shall ensure the Employer
is indemnified from all claims arising therefrom.
The Contractor shall give warning each time of his intention to blast and shall station personnel on the
roads and elsewhere with flags, horns and whistles and prevent persons, animals and traffic entering
or remaining within the danger zone. He shall arrange for control of traffic on main roads by the
Ethiopian police during all blasting operations within 400m of such main roads.
The Contractor shall furnish and erect special signs to warn the public of his blasting operations. Such
signs shall be placed at appropriate points within the project limits, shall be maintained so as to be
clearly visible to the public during all critical periods of the blasting operations, and if blasting is by
means of electronic detonators, it shall include a warning facility to have radio transmitters turned off.

(d) Licenses
The Contractor's representative in charge of blasting operations shall have a current license held valid
by the appropriate authority in Ethiopia for all types of blasting required, including restricted blasting,
and the license shall be made available to the Engineer for verification.
(e) Storage
The Contractor shall provide proper buildings in suitable locations for the storage of explosives to the
satisfaction of the Engineer and any statutory regulations in force in Ethiopia. Such storage locations
shall be clearly marked with “Danger Explosives” signs in bold script in all languages normally spoken
on Site.
(f) Precautions to be taken

The Contractor shall take all proper precautions and comply with all laws or other statutory regulations
governing the handling and use of explosives including the display on Site of warning notices
explaining the procedure to be used in blasting operations. Such notices shall be displayed in all
languages normally spoken by the personnel working on Site.
The Contractor shall select the number, position, orientation, depth and spacing of holes for blasting;
the amount and type of explosive to be used per hole; and the number and sequence of delays, such
that fracturing (or otherwise) that damages the ground below or beyond the required excavation limits,
is avoided. Final holes shall stop short of the final limits of excavation by the amount required to
ensure that, after detonation and the removal of all loose material, the final surface is in the correct
position.
In areas where it is necessary to restrict blasting in order to protect installations of significance or

whenever there is a need to blast within 400m of any public road, railway line, overhead power line or
telephone line, the Contractor shall:
 Inform the Authority concerned of his intention to carry out blasting within the vicinity of their
property;
 Ensure that all conditions imposed by the Authority, including attendance by the
representatives of such Authority, are met;
 Provide cover to the area to be blasted, to the approval of the Engineer and the Authority
concerned, to prevent damage by flying debris to such services;
 Ensure, by the use of controlled delayed detonations or by limiting the amount of charge used
at any blasting site, that the peak particle velocity at any existing building, structure or service
does not exceed 50m/s;
 Provide a suitable vibrometer and, whenever called upon to do so by the Engineer,
demonstrate by the use of this instrument that the charges he proposes to use comply with
this Specification.
 The Contractor should not use explosives at close proximity to schools, hospitals, rural towns
and settlement areas. Blasting activities, within the RoW or road reserve for widening or
alignment improvements (ie if blasting is required in the middle of the road under construction
or to be built), should be done with controlled blasting options.
Warning shall be given well in advance to the local police office/s, administrative office/s concerned as
well as local communities each time the Contractor intends to blast. The Contractor shall obtain written
approval of blasting from the said office/s at least one (1) week before the actual blasting, without
which the Engineer will not approve the blasting. Personnel of the Contractor shall be stationed on the

road and elsewhere with flags, horns and whistles and shall prevent persons, animals and traffic
entering the danger zone.
Rock blasting near settlement areas shall be properly coordinated with the relevant officers of the local
Authorities in an attempt to minimise levels of noise pollution and community interference.
Blasting should not be done during the night time, at any locations.
Neither the Contractor's compliance with these restrictions nor any approval given by the Engineer
shall relieve the Contractor of any of his liabilities or responsibilities in respect of any damage to any
building, structure or service resulting from his use of explosives.
Notwithstanding all of the above, the Contractor shall cease blasting and continue excavation in rock
by barring, wedging or other approved methods, whenever called upon to do so by the Engineer.
If firing is to be done electronically, all precautions shall be taken to prevent premature detonations. If
blasting is to be carried out in the vicinity of overhead electrical power cables, the licensed
representative of the Contractor shall check for stray electric currents at the blasting site prior to laying
charges.
All personnel, other than the licensed representative of the Contractor and one skilled person, shall
withdraw to a safe distance before firing wires are connected to the firing cable. The connection of the
firing cable to the firing battery shall be the last operation. No charging or firing shall be permitted
when there are electrical storms or audible thunder claps in the vicinity of the blasting site.
After blasting no person shall approach the danger zone until the blasting site has been examined by
the licensed representative of the Contractor or other responsible person and, in the case of misfires,
before the proper precautions have been taken.
The Contractor shall keep records of all blasting carried out showing the time and location of each
blast, the type and amount of explosives used and any other relevant data. Copies of these records
shall be sent to the Engineer on a weekly basis and shall relate to the previous week's work.
Before the beginning of the Defects Notification Period, on completion of the Works, or when ordered
by the Engineer, the Contractor shall remove all unused explosives from the Site and shall submit
written confirmation of compliance with this instruction to the Engineer.
1211 Photographic Records

The Contractor and Engineer shall jointly make photographic and other records of the surfaces and
condition of the Site, as agreed by the Engineer, immediately prior to entering the Site for the purpose
of constructing the Works. The records must include all work sites including borrow pits, quarries,
campsites, access roads and diversions, water sources etc. The Contractor shall send a signed, hard,
colour copy of these records to the Engineer on their letterhead along with a digital copy of the records
on compact disc or similar.
After commencement of the Works, the Contractor shall take not less than thirty-six (36) monthly
progress photographs as agreed with the Engineer. These shall be in an approved digital format and
shall be forwarded to the Engineer on compact disc or similar.
 All photographs provided by the Contractor shall be labelled in a manner approved by the
Engineer with the following data:
o Project name and reference number;
o Date of exposure (automatically recorded on the photograph);
o Photograph identification number, brief description, chainage, location and direction of
view.

The Contractor shall also provide and maintain digital cameras, complete with charging facilities;
approved software for labelling/cataloguing photographs; and compact discs for preparing back-up
records, for the use of the Engineer for the duration of the contract.
The Contractor shall take digital photographs and videos of all sites, including materials sites,
campsites, access roads and diversions prior to commencement of construction or civil works and
every month thereafter. These photographs shall be filed with the necessary footnotes (eg subject,
date and time, name of the photographer, km location, distance and direction from the project road,
etc.) for future review by the Engineer and the Employer.
The Employer shall hold the copyright of all these photographs which shall not be used for any other
purpose without the approval of the Employer.
Some of the key photographs shall be attached to the monthly progress reports and the updated
Environmental Management Plan (EMP) and/or environmental monitoring reports as required. This will
enable the monitoring of the impact of the construction works on the natural and social environment.
The digital capturing of sites shall include areas which are environmentally important and attractive,
both before and after construction works. These shall include environmentally responsive road design
elements; adverse or negative impact of the road construction on the environment such as failures to
slopes and structures; mismanaged road areas; overall management of the road corridor; and best
practice undertaken along the project road.
Photographs of active material sites and those that have been reinstated shall be submitted to the
Engineer together with other relevant site photographs.
1212 Working Drawings

The Contractor shall submit to the Engineer for his approval, at least fifteen (15) days before their
proposed use, three printed copies of all working drawings such as stress sheets, shop drawings,
erection plans, false work plans, cofferdam plans, bending diagrams for reinforcing steel, or any other
supplementary plans or similar data necessary for construction of the Works as agreed with the
Engineer. The drawings shall be A3 size in general conformity with the requirements of the Technical
Specifications, the tender drawings and the requirements of the Engineer.
The Engineer shall request changes by marking up the changes required on one (1) copy of the
drawings submitted by the Contractor and by returning the marked-up copy to the Contractor for
rectification by the Contractor. The Contractor shall incorporate the changes and submit three (3)
printed copies and one (1) digital copy of the revised drawings to the Engineer.
The Contractor shall immediately notify the Engineer in writing of any objections to changes requested
by the Engineer. The final decision of the Engineer shall be communicated in writing to the Contractor
within fifteen (15) days and the Contractor shall abide by the decision.
1213 As-Built Drawings

The Contractor shall prepare satisfactory as-built drawings for all aspects of the Works, three (3)
printed copies of which shall be submitted to the Engineer for review no later than thirty (30) days after
completion of the Works. These drawings will be of A3 size and generally follow the same format as
the construction drawings.
The approved as-built documentation when submitted to the Employer by the Engineer shall include,
but not be limited to, the following finalised documents:
 Plan and Profile drawings;

 Cross-Sections drawings;
 Minor road intersections drawings;
 Bridge drawings;
 Reinforced Concrete Box Culverts, and Reinforced Concrete Pipe Culverts Drawings;
 Itemised Cost of Revision;
 Variation Orders;
 Description and justification for major changes in quantities;
 Photographic report showing changed site conditions.
The Engineer shall request changes by marking up the changes required on one (1) copy of the
drawings submitted by the Contractor and by returning the marked-up copy to the Contractor for
rectification by the Contractor. The Contractor shall incorporate the changes and submit three (3)
printed copies and one (1) digital copy of the revised drawings to the Engineer.
The Contractor shall immediately notify the Engineer in writing of any objections to changes requested
by the Engineer. The final decision of the Engineer shall be communicated in writing to the Contractor
within fifteen (15) days and the Contractor shall abide by the decision.
1214 Project Signboard

The Contractor shall, within six (6) weeks of the receipt of the Letter of Acceptance, provide and erect
two (2) project signboards bearing project details in English (and in the local language/s) as indicated
on the Drawings at locations directed by the Engineer. The Contractor shall maintain the signboards in
good condition. At the end of the Defects Liability Period, the Contractor shall remove the signboards
from the Site.
The provision of project signboards shall be considered among the Contractor’s general obligations
and shall not be paid for separately.
1215 Occupational Health and Safety Programme

This Clause should be read in association with Clause 1613 of these Specifications.
Due precaution shall be taken by the Contractor, and at his own cost, to ensure the health and safety
of his staff and labour, the staff of the Engineer and any personnel visiting the work Site.
The Contractor shall ensure the availability of first-aid services for all site personnel, including the staff
of the Engineer and visitors, and shall provide a vehicle to act as an ambulance for emergency cases.
The Contractor shall provide protective equipment such as helmets, safety harness, masks, goggles,
gloves, and safety footwear for workers, the Engineer’s staff and permitted visitors at hazardous sites
such as quarry and crusher sites. At the hazardous sites, workers, Engineer’s staff and permitted
visitors shall not enter any workplaces without appropriate protective clothing. The Contractor, at his
own cost, shall provide adequate numbers of helmets, protective clothing and equipment to his
Workforce, the staff of the Engineer and permitted visitors.
If the road traverses through malaria endemic areas, the Contractor shall take all necessary
precautions to ensure that his staff and the staff of the Engineer are aware of the situation and
adequately protected. This will include environmental health and hygiene management at camp sites
and shall provide a clinic, chemically treated mosquito nets and medicines for the workforce. The
Contractor shall not induce malaria outbreaks by creating temporary and permanent water holding
areas which favour mosquito breeding. When restoring and reinstating the borrow pits and quarry
areas, the Contractor shall ensure that any breeding sites for mosquitoes are eliminated.

The Contractor shall provide clinics with all necessary medication at major construction camps; first-
aid kits appropriate to the nature of the work and unforeseen accidents likely to occur at all working
sites; and shall provide education to personnel of the Contractor about safety procedures and
emergency response plans associated with their task.
(a) First-Aid Facilities

The Contractor shall employ on the Site, during the execution of the Works, one competent and
qualified first-aid practitioner with at least five (5) years’ experience in first-aid and hygiene.
The Contractor shall provide the first-aid practitioner with a stock of medicines and medical equipment
of a scope, quantity and standard deemed adequate by the appropriate medical authorities, and shall
keep such stock and equipment replenished and in good order.
The Contractor shall provide and maintain an adequate number of well-stocked first-aid kits at suitable
locations on the Site, in the Engineer’s vehicle, and in the vehicles of his own staff. These kits shall be
regularly replenished on depletion or if out of date.
(b) Accident Prevention Officer

The Contractor shall have on his staff at the Site, an officer with five (5) years’ experience with specific
responsibility for all matters related to the safety and protection of all staff and labour of the Contractor
and Sub-Contractors, staff of the Engineer and permitted visitors. This officer shall be qualified in
accordance with set standards for this work and shall have the authority to issue instructions including
taking protective measures to prevent accidents. The Accident Prevention Officer shall be on Site for
the full duration of the contract.
(c) Epidemics
In the event of any outbreak of illness of an epidemic nature the Contractor shall comply with and carry
out such regulations, orders and requirements as may be made by the Government, or the local
medical or sanitary authorities for the purpose of dealing with and overcoming the same.
(d) Fire Protection

The Contractor shall take all appropriate measures for the prevention of and protection against
fire on the Site during the performance of the Works. The Contractor shall provide and maintain
an adequate number of appropriate fire extinguishers at suitable locations on the site, in the
Engineer’s vehicles and in the vehicles of his own staff.
(e) Records of Health and Safety

The Contractor shall maintain such records and make such reports concerning safety, health and
welfare of persons and damage to property as the Engineer may, from time to time, prescribe.
(f) Reporting of Accidents

The Contractor shall, within 24 hours of the occurrence of any accident at or about the Site or in
connection with the execution of the works, report such accident to the Engineer. The Contractor shall
also report such accident to the competent authority whenever such report is required by law.
1216 Participation of Women

A policy of promoting the employment of women at all levels of the management and execution of road
works projects shall be implemented. Requirements for female participation of the key personnel of the
Contractor and the Workforce shall be specified in the Contract.

Where reasonable and practical, qualified female Workforce shall be identified in the project area, and
to the extent possible, be offered vocational training to supplement their skills and improve their
qualifications for recruitment.
1217 Temporary Diversions

Prior to the construction of temporary diversions, the Contractor shall, in consultation with the
Engineer, the Employer, local police and administrative offices, consult with local community
representatives regarding the retention or the demolition of the diversion/s after the construction works
and prepare a letter of confirmation to the local authority.
In the case of an agreement to demolish the temporary diversion, upon completion of the main
construction works, at a particular section of road, the ground shall be reinstated to its original
condition.
1218 Haul and Access Roads

As much as possible, haul and access roads should be accommodated within or adjacent to, the
existing roads. In villages and towns, existing roads may be improved and used as access, providing
this will not create undue interference to the existing traffic movements within these communities.
Should it not be possible to locate haul and access roads in or adjacent to existing roads (eg through
farmland and grazing land), new locations should be thoroughly investigated.
The reinstatement of haul and access roads should begin once the decision has been made by the
Engineer in writing to the Contractor that these roads are no longer required. Reinstatement should
begin at latest one (1) month after receipt of such instruction from the Engineer and should be
completed within two (2) weeks.
If haul and access roads are established in farmland or grazing land away from the existing roads,
then the following steps shall be taken toward their reinstatement:
 Preservation of the top soil during the construction of haul and access roads;
 Removing the selected materials used for construction of the access road (disposal shall be
as per the direction of the Engineer);;
 Loosening the compacted soil using ripper; and
 Finally spreading the preserved topsoil so that it allows re-vegetation.
1219 Royalties
The Employer shall be responsible for agreement and payment of compensation and any royalties in
respect of land for permanent works, temporarily occupied lands, spoil areas, working areas, borrow
areas, quarries, pre-cast yard areas, road diversions and sites for the Contractor’s and Engineer’s
accommodation unless otherwise specified in the Particular Specifications.
1220 Site Meetings and Reporting

It is the duty of the Contractor to participate in Site meetings. The Employer and the Financier are
also entitled to attend Site meetings through their representatives whenever they require.
The purpose of the Site meetings is to coordinate the Works with the Contractor, to evaluate the
progress of the Works, to solve major problems encountered and to record agreements made
thereupon.
The Engineer shall arrange for the first Site meeting where future meetings shall be scheduled on a
regular (monthly) basis. The Engineer shall also prepare and issue the agenda and notice of
meetings, and minutes of the meetings. The minutes of the Site meeting shall be issued within
fourteen (14) calendar days after the meeting and shall be numbered consecutively. Minutes shall be
deemed to have been received by the Contractor unless the Contractor gives notice at the next
meeting that the minutes were not received.
Any objections to the minutes of the Site meeting shall be given in writing to the Engineer within two
(2) days of receipt of the minutes.
Agreements recorded in the minutes of the Site meetings are binding to all parties if objections to the
minutes have not been given in due time.
The Contractor shall prepare a mobilisation report on the environmental and social safeguards at start-
up, including reports on any mobilisation workshops along with other workshops and awareness
activities related to safeguards, sites and road safety and health provision and any other aspects
required in the contract.
Progress Reports shall be prepared monthly using the Employer’s standard report formats, to detail
progress against the Works programme in respect of all project elements and hard outputs, with
relevant site photographs. The reports shall include details of the implementation of Environmental
and Social Safeguard measures. All monthly project correspondence shall be submitted in soft copy
together with the monthly progress reports.
Quarterly progress, annual and contract completion reports should also include discussion of
environmental, social and safety issues.
Agendas for all site meetings, which will be held every month, should include detailed environmental
and social issues related to the road construction works.
1221 Measurement and Payment

Work performed as part of the obligations within this Division shall not be paid separately and the cost
thereof is deemed to be included in other pay items and rates.

Division 1300: Contractor's Establishment on Site
1301 Scope
This Division covers all work involved in the establishment of the Contractor's organisation, camp(s)
and plant and equipment on or adjacent to the Site, and the removal thereof after completion.
1302 General Requirements
a) Camps, equipment and testing facilities

The Contractor shall establish his construction camp on the Site. This will include all accommodation,
sanitary conveniences, maintenance and testing facilities necessary for his personnel, plant,
equipment, stores, process control, etc.
The Contractor shall bring all necessary plant, equipment and personnel to the Site prior to the
commencement of the Works, and remove the same from the Site after completion of the Works
leaving all areas that have been occupied in a clean and tidy condition to the satisfaction of the
Engineer.
It is the Contractor's responsibility to identify a suitable Site with provision for:
 The Site Engineer's office;

 Laboratory facilities and working areas; and
 Camp sites for himself and his senior and junior staff, including houses, offices, labourers'
accommodation, etc.
All camps shall be located with the prior approval of the Engineer in collaboration with the Employer’s
department responsible for Environmental Monitoring and Safety and local officials at appropriate sites
taking into consideration, not only the permanent works but also the peculiar environmental and social
situation of the area. Camps shall not be located within or in the proximity of urban centres, on fertile
farmlands and forested lands that are either owned by Farmers’ Cooperatives, Government
Organisations, (eg Forestry Priority Areas and other sensitive areas such as ecological sites; dense
forests; banks of water sources; and within wetland ecosystems) or NGOs. They shall be located at
least 1km away from streams and rivers.
Prior to the establishment of the camp and other facilities, the Contractor shall, in association with the
Engineer and Employer’s department responsible for Environmental Monitoring and Safety, consult
with local authorities, administrative offices and representatives of local communities on the possible
future utilisation of such camp facilities for the local community(ies). If agreed, the Contractor shall
prepare a confirmation letter regarding the future hand-over conditions of such facilities to the local
community(ies). A copy of the letter shall be attached to the monthly progress report for record
purposes.
Crusher plants and workshops shall be located away from dwelling blocks in the camp, leaving an
adequate buffer zone to curb air and noise pollution effects to the workers. The choice of all sites for
the establishment of camps shall be subject to the approval of the Engineer. Crusher and asphalt
plants shall be located at least 1 km from settlement areas
In addition to any other requirements, and to the satisfaction of the Engineer, the Contractor shall:
 Provide an adequate potable water supply both for drinking and sanitary use in the camps to
World Health Organisation (WHO) standards;
 Provide adequate toilet facilities and garbage bins for all the labour force in the camps;

 Provide adequate fire-fighting facilities/fire extinguishers at each block in the camps and
periodically maintain as per the requirements of the supplier’s standard procedures;
 Confine all liquid waste and solid waste to a suitably designed and constructed storage facility
(such as septic tanks, pit-latrines, containers for garbage wastes) until removed from the site.
The liquid waste generated in the camps will be conveyed to a designated treatment site or
treated on site prior to discharge into the environment;
 Ensure the safe and effective disposal of sewage from the camp sites and treatment of
latrines;
 Ensure the safe and effective disposal of waste and garbage. Oils and greases shall be
recycled or disposed of by burning and solid waste shall be disposed of by burning or by
burial. Under no circumstances will disposal on the surface or to water courses be tolerated;
 Provide all project personnel with suitable prophylactics for the prevention of STD and
HIV/AIDS, and diseases associated with insects and pests;
 Establish reasonably equipped and staffed health clinics at each camp depending on the
number of workers accommodated at each site and as required by the Particular
Specifications;
 Employ only qualified drivers and operators; provide refresher training; ensure careful and
responsible driving and operation; apply speed limits in settlements, on open roads and
through construction areas. Violation of speed limits and driver safety shall render the
operator or driver subject to dismissal;
 Liaison and regular consultation with the affected local communities in order to promote good
community relations, including the establishment of a Project Liaison Committee (PLC) (see
Clauses 1615 and 1616;
 Ensure that the servicing and repair of all plant and vehicles, whether hired by the Contractor,
or owned by him, is carried out in his site compound and not on the Works Site;
 Submit proposals to the Engineer for approval and subsequent recommendation to the
Employer for the location of temporary diversions, access roads, haulage roads, camps and
borrow pits;
 Ensure that all quarries and borrow pits shall be trimmed and drained to the approval of the
Engineer to ensure that no ponding of water remains.
The Employer shall be responsible for all negotiations and compensation to property owners. To this
end, the Employer requires up to three (3) months for the acquisition of land in rural areas and up to
four (4) months in urban areas. Under no circumstances shall the Contractor enter property outside
the road reserve without written confirmation from the Engineer/Employer that the necessary
negotiations with the property owner have been satisfactorily concluded.
Camps proposed by the Contractor shall be subject to review and approval by the Engineer and the
Employer’s department responsible for Environmental Monitoring and Safety. The camps shall be
located to minimise disruption to local population, fauna, flora and watercourses.
On completion of construction, the Contractor shall be responsible for the complete reinstatement, at
his own cost, of all property that he has occupied, used, damaged or destroyed during the course of
the contract. The Contractor shall also dismantle and remove the camp, laboratory and workshop and
reinstate these areas to the approval of the Engineer.
Photographs of the proposed camp site(s) before and after construction (including the reinstatement of
the site) shall be taken in order to monitor the environmental impact over the life span of the camp site.

These photographs shall be dated and filed chronologically, and made available at any time for review
by the Engineer and the Employer/Client.
Any tree removal activities for camp sites shall be undertaken on the approval of the Engineer in
collaboration with the local Forestry Department. Before removing any tree, the Contractor shall
survey the number, size and types of trees/bushes to be removed. In consultation with the Engineer
and local Forestry Department, the Contractor shall plant replacement trees and additional trees
during site establishment and at appropriate locations during reinstatement.
All camp sites shall be established with appropriate and standard sanitation facilities including lined
septic tanks to reduce possible pollution impact on ground and surface water resources. The
Contractor shall dispose of all waste from the camp in designated or authorised places and shall take
all necessary measures and precautions to avoid any nuisance or disturbance to inhabitants arising
from establishment, operations and reinstatement of the camp work sites.
If the camp sites and related facilities are not going to be used for other purposes and are going to be
demolished, the Contractor shall remove the entire superstructure as well as the foundations of all
buildings and reinstate the campsite to its original state. The reinstatement activities for camp sites
shall include stockpiling the top soil during establishment, removal of all concretes/slabs and all scrap
metals from the workshops, loosening the compacted soils, and replacement of the stockpiled top soil.
b) Legal relations and responsibility to the public

The Contractor shall take all steps necessary to comply with the terms of the Conditions of Contract,
particularly in respect of the insurances and indemnities required, and shall comply with all regulations
of Statutory Authorities.
c) Electricity Supply
The Contractor shall provide and maintain his own electrical supply. This supply must be adequate to
supply the areas set aside for the housing and offices of his own staff and those of the Engineer and
his staff.
The Contractor shall provide and maintain all necessary temporary power and lighting and all
associated equipment for the duration of the Contract.
Once equipment becomes redundant, and with the approval of the Engineer, the Contractor shall
disconnect and remove said equipment and make good any affected areas.
d) Laboratory
(i) General
The Contractor shall provide, erect and maintain for the duration of the contract, a laboratory on site
for his exclusive use, in order for him to undertake all necessary tests as described in the
specifications.
(ii) Access to the Contractor’s laboratory by the Engineer
The Engineer shall have full and continuous access to the Contractor’s laboratory as necessary for
reviewing and monitoring the tests undertaken for the works.
e) Handing over of the Site

The Site shall be handed over to the Contractor in accordance with the Conditions of Contract.


The tendered rate for the specific pay items shall include the general requirements of Series 0000.
Item 13.01 Contractor establishment

a) Fixed Cost ......................................................................................................................... Lump Sum
b) Time-related Cost ..................................................................................................................... month
Payment of the lump sum item 13.01(a) shall be made in three instalments, as follows:
 The first instalment, 50% of the lump sum, shall be paid in the first payment certificate after
the Contractor has met all his obligations under this section and has made a substantial start
with the construction in accordance with the approved programme;
 The second instalment, 30% of the lump sum, shall be paid when the value of the work done
reaches half (½) of the contract price, excluding contingencies and price adjustments in the
Conditions of Contract;
 The third and final instalment, 20% of the lump sum, shall be paid when the Works have been
completed and the Contractor has reinstated the Site in accordance with the Contract.
The item coverage for the tendered rate for sub-item 13.01(b) shall include full compensation for that
part of the Contractor's general obligations, which are mainly a function of construction time.
The tendered rate will be paid monthly, pro rata for parts of a month, from the date on which the
Contractor has received a written instruction, in terms of the General Conditions of Contract, to start
the Works, until the end of the period for completion of the Works, plus any extension thereof as
provided in the Conditions of Contract, provided that:
(1) Should the works be certified as having been completed before the contractual date for
completion of the works, the Contractor will then be entitled to payments in regard to the unexpired
period for completion;
(2) Should the progress of the Contractor in terms of the value of work done be in arrears in
regard to his approved original programme, payments in respect of this item may be limited to
payments for that period, which, in his original programme (after suitable adjustments in respect of the
extension of time granted) agrees with the actual value of work done.

Division 1400: Accommodation, Services, and Attendance for

the Engineer's Staff
1401 Scope
This Division covers the provision of site facilities for the Engineer’s supervisory staff in term of
accommodation and transport. The accommodation shall include the necessary office and
laboratory accommodation, houses and quarters for employees and the provision of the
required furniture, equipment and services.
The Division sets out three options for the Engineers accommodation covering the needs of
large, medium and small projects. The Particular Specifications shall state the option that
applies and any specific amendments to that option as required and approved by the Engineer.
1402 General
The Engineer’s offices and laboratory shall be erected by the Contractor on the Site (or on land
which has been approved by the Engineer and the Employer for this purpose) and in close
proximity to the Contractor's offices and laboratories. If the Contractor decides to move his own
offices and/or laboratories to a new site, the offices, laboratory and other buildings erected for
the use of the Engineer shall be rebuilt by the Contractor near the new site if required, at no
additional charge.
Unless otherwise specified in the Contract, the Contractor’s main camp and the Engineer’s
office, laboratories and housing shall be located in the central one-third of the length of the
Works and shall be located in such a manner as to minimise disruption to the local population,
fauna and flora, and water courses. Adequate drainage facilities, treatment of sewerage and
waste disposal shall be provided. Camps shall be dismantled and rehabilitated on completion of
the Works.
The Contractor shall not commence construction of the Works before the minimum required
equipment, as agreed by the Engineer, has been provided.
The Contractor shall take all reasonable precautions to prevent unauthorised entry and ensure
the general security of the Engineer’s offices and laboratories.
The layout, siting and orientation of the housing, offices and laboratory or other accommodation
shall be to the Engineer's approval and shall be decided upon in consultation with the Engineer.
Offices, laboratories, residential accommodation complete with their contents, access roads
and hard standings shall be ready for occupation and use by the Engineer within one hundred
and twenty (120) days of the date for commencement of the Works unless otherwise described
in the Contract. If the Contractor fails to provide the housing, offices and laboratories within the
time frame stated herein, the Contractor shall continue to provide the temporary housing,
offices and laboratories at the Contractor’s own cost. This is without prejudicing the Engineer’s
right to take other contractual measures.
All offices, testing laboratories and residential accommodation shall be regularly cleaned for as
long as they are in use. Suitable arrangements shall be made for the disposal of waste arising
from the offices, testing laboratories and residential accommodation.
All equipment for offices, testing laboratories and residential accommodation shall be of a
quality and precision appropriate to its use and shall be delivered new to the Engineer. The

Contractor shall keep all equipment in good condition and shall repair or replace, as instructed
by the Engineer, any equipment that becomes defective or unserviceable. All the equipment
shall first be calibrated by a competent Authority of the country. Furthermore, the Contractor
shall ensure that any equipment needing periodic calibration shall be calibrated on delivery,
annually and at other times as and when required by the Engineer.
The Contractor shall provide suitable accommodation to enable Engineer’s staff to satisfactorily
carry out their duties during the manufacture and/or testing of off-Site Works components.
All the Engineer’s site facilities shall be located as directed by the Engineer. The Contractor
shall, as part of the bid, submit a proposed plan regarding the Engineer’s site facilities. Water
and electric supply shall be provided on a 24-hour basis and the Contractor shall pay for any
statutory charges associated therewith. Pure drinking water shall be supplied or made available
for all the facilities.
The Contractor shall start work on the Engineer’s site facilities as soon as practical after the
date of commencement of the Works. If the Contractor fails to provide the Engineer’s living
accommodation, offices and laboratories within the timeframe specified herein, the Contractor
shall, at his own cost, provide and maintain temporary living accommodation, offices and
laboratories of similar size and with similar furniture and equipment as acceptable to the
Engineer.
Detailed specifications and plans regarding the site facilities, including, but not limited to, their
services, equipment, furnishing and vehicles shall be supplied by the Contractor to the
Engineer within 30 days from the date of commencement of the Works.
a) Ownership of Engineer’s Site Facility

The ownership of facilities supplied to the Engineer on completion of the project shall be as
shown in Table 1402/1 unless otherwise specified in the Particular Specifications.
Table 1402/1: Ownership of Engineer’s Site Facilities

Item Description of Facilities Ownership
1 Office building Employer
2 Laboratory building Employer
3 Houses Employer
4 Furnishings and equipment for houses Contractor
5 Furnishings and equipment for offices Contractor
6 Laboratory equipment Contractor
7 Surveying equipment and accessories Contractor
8 Communication equipment and radios Contractor
9 Vehicles Contractor
1403 Office and Laboratory Accommodation
a) General
The Engineer’s offices and laboratory, including their appurtenant services shall be constructed
in accordance with national and local regulations and practice in Ethiopia. The Contractor shall
prepare and submit for approval by the Engineer, detailed designs and drawings of his proposal
in terms of the Engineer’s facilities in accordance with the guidelines shown in the Standard
Drawings and provided in this Specification.

Building walls shall be prefabricated in accordance with the drawings and constructed from
approved prefabricated elements, hollow blocks or other approved materials. The construction
material to be used shall be strong, durable and of an acceptable quality.
The ceilings of the buildings shall be of plaster-board or any other suitable material approved
by the Engineer. Glass fibre insulating material shall be provided on top of the ceilings.
All rooms in the buildings shall have a minimum clear height (the height between floors and
ceilings) of 2.7 m. All windows shall be of the type that can open over the full window area and
they shall be fitted with self-closing insect screens.
Each building shall be provided with a veranda on one side, running for the full length of the
building. The veranda shall be 1.5m wide and shall have a 100mm thick concrete floor.
The Contractor shall provide access roads, fencing and areas of hard standing around the
offices and laboratory buildings; water and power supplies; external security lighting;
telephones (to office, laboratory and Type A and B housing as may be specified in the Bill of
Quantities) and sewerage services; and arrange for the disposal of refuse, all subject to the
approval of the Engineer. The compound shall be properly drained and landscaped to enhance
its appearance and prevent standing water in periods of wet weather.
The area for the Engineer's office and laboratory shall be secured with a 2.0 m high chain link
fence topped with barbed wire overhang and with a 5m wide gate secured with a padlock and
chain.
Office and laboratory buildings shall be painted with an approved paint after erection. The
paintwork shall be maintained by the Contractor throughout the period of the Works; including
the Defects Liability Period or whenever required by the Engineer.
Venetian blinds, which are adjustable so as to permit light to enter a room but excluding direct
light, shall be provided for each window.
Two suitable fire extinguishers and two fire axes shall be provided for each building. Fire
extinguishers shall be of the BCF (Bromochlorodifluoro-methane) type manufactured to
BS 1721 and suitable for Types A, B, C and E fires. The extinguishers shall contain no less than
2.5 kg of extinguisher fluid and shall be fitted to the wall at a suitable position by means of quick
release brackets. They shall be freshly charged and the seals shall be unbroken. They shall be
periodically checked and charged in accordance with the manufacturer’s instructions.
Carports shall be so constructed that vehicles parked under them shall at all times be protected
from the direct rays of the sun. They shall have corrugated galvanised iron (CGI) roofs, or
similar approved material. The configuration and layout of carports to be provided adjacent to
the Site laboratory and Engineer's office buildings shall be of sufficient number and size to
accommodate all the vehicles of the Engineer. Their floors shall consist of a layer of crushed or
broken stone to alleviate dusty and muddy conditions.
A sewerage system shall be provided, including septic tanks and soakaways, if necessary.
Such tanks and soakaways shall be deemed to be part and parcel of the accommodation
provided and in respect of which no separate payment shall be made.
The Contractor shall be responsible for regular cleaning and maintenance of the site laboratory
and Engineer’s office buildings and of the plots on which they are situated. Clearing of
vegetation and cutting of grass inside boundary fences, including their disposal, shall be carried
out on a periodic basis to the satisfaction of the Engineer. The Contractor shall be responsible
for providing sufficient labour, tools, brushes, mops, buckets and cleaning products to comply
with these requirements. The Contractor shall be deemed to have made allowances in the
relevant pay items of the contract for the running and maintenance of the site laboratory and
the Engineer’s office.

If the Contractor fails to maintain the buildings, access roads and parking areas and to provide
the services specified, after due warning by the Engineer, the Engineer may withhold all or part
of the monthly payments due under pay item 14.04(b).
b) Air Conditioning Units
The Contractor shall provide and install cooling and heating air-conditioning units to offices and
laboratories. The air conditioners shall have a nominal cooling and heating capacity of 12,000
BTU/hr. The cooling and heating power consumption of the air-conditioning units shall be at
least 2.1 kW and 1.7 kW respectively.
c) Offices
The Contractor shall provide, furnish, equip and maintain an air-conditioned office(s) for the
sole use of the Engineer for the duration of the contract. The Engineer's office building shall be
constructed as shown on the drawings or as instructed by the Engineer. It shall have a
2 2 2
minimum area of 220 m for large contracts; 145 m for medium contracts; and 50 m for small
contracts (excluding the area of the corridor and veranda). The total area of window spaces
shall be a minimum of 15% of the floor area of the office building. The various sizes of the
offices required shall be as shown on the drawings or specified in Table 1409/5 of these
specifications and as approved by the Engineer.
Office buildings shall have concrete floors with vinyl floor tiles or similar approved by the
Engineer.
All rooms shall be provided with electric fluorescent strip lighting of a minimum power rating of
120 W per room. Two (2) 15 ampere double power points shall be provided in each office and
in the kitchen, and one (1) in the corridor.
A piped potable water supply shall be provided to toilets, hand wash-basins, and to the kitchen
which shall contain a sink with suitable built-in cupboards and working surfaces. A hot water
supply shall be provided to both the kitchen sink and toilet hand wash-basins. Where necessary,
and approved by the Engineer, an elevated tank with adequate capacity to supply water to
houses, offices and laboratory shall be provided. If there is no existing waterborne sewerage
system, sewerage shall connect to a septic tank at least 30m from the building.
The conference room shall be furnished with at least a conference table, chairs, black/white
board, and a side cabinet.
The store shall be fitted with shelving to the approval of the Engineer.
The Engineer’s office shall be provided with independent external telephone connections with
extensions to each office in the office and laboratory buildings. A complete facsimile service
with a dedicated telephone line and fax paper, full international telephone service and internet
connections shall also be provided. The rates in the Bill of Quantities shall include the cost of all
telephone calls in connection with the project administration, the maintenance of the services
and any other costs associated with the service.
The Contractor shall supply new surveying equipment for the sole use of the Engineer on site
within four (4) months from the date of commencement of the Works contract. The Contractor
shall provide two-way radios of the type suitable for satisfactory communication during the
carrying out of surveying works, and as approved by the Engineer, each with spare batteries
and charging units. In addition, all necessary equipment such as staffs, range rods, tapes,
pegs, and other items necessary for checking surveys, setting out and measurement of the
works shall be supplied by the Contractor.
All office fittings, furniture and equipment shall be new and shall be maintained in full working
order throughout the Contract period. Sufficient consumable items shall be supplied with the office
facilities and shall be replenished when requested by the Engineer. The tendered amounts shall
include the costs for maintenance and replacement of any of the fittings, furniture and equipment
throughout the Contract period.
The Engineer’s offices shall be equipped with the fittings, furniture and equipment as shown on
the drawings or specified in Tables 1409/1 and 1409/2 of these specifications and as approved
by the Engineer. Substitution of type may be made only upon approval of the Engineer.
d) Laboratories
The Contractor shall provide, furnish, equip and maintain an air-conditioned site laboratory
adjacent to the Engineer’s office building for the sole use of the Engineer for the duration of the
contract. No permanent construction work will be permitted to begin until laboratories and
appropriately trained staffs have been provided.
The Contractor shall provide and install in the laboratory all the necessary equipment,
apparatus and materials for the performance of all the standard tests required for testing and
control of the works and materials as required in these specifications.
The Engineer's laboratory building shall be constructed as shown on the drawings or as

2 2
instructed by the Engineer. It shall have a minimum area of 210 m for large contracts; 120 m
2
for medium contracts; and 70 m for small contracts. The various minimum sizes of the
laboratories required shall be as shown in Table 1409/6 of these specifications.
The total area of window spaces shall be a minimum of 15% of the office floor areas and 10%
of the floor area of the laboratory working area.
The floor of the laboratory building shall be constructed of reinforced concrete with a power
floated U3 finish as specified in Clause 8207. Concrete working floors shall be at least 125 mm
thick. A reinforced concrete floor panel of size 4 m x 4 m and of total thickness 0.4 m for use as
a compaction area shall be provided. Where required, concrete footings and pedestals shall be
constructed to the dimensions indicated by the Engineer for installing certain testing equipment.
For example, reinforced concrete plinths shall be provided for the concrete crushing and CBR
machines.
Concrete paving slabs shall be laid around the laboratory building over a width of 2.0 m.
Adjacent to the laboratory building, the Contractor shall provide a separate covered drying
shed. The drying shed shall have a minimum floor area as shown in Table 1409/6. It shall be
constructed of raised concrete floor and weatherproof roof but open on all sides.
Sturdy metal-surfaced benches with integral cupboards below, and sturdy shelving above, shall
be provided in the laboratory working area. The laboratory store shall be fitted with suitable
shelving all to the approval of the Engineer.
Shelf space provided against walls shall be well constructed and supported to accommodate
heavy items. Shelving shall be in a suitable timber or steel material as required. Shelving below
work tables shall be 390 mm above floor level. Shelving above working areas shall be 1980 mm
above floor level.
Work bench areas shall be of two types as may be required:
 Wooden construction - the tops shall be hard and smooth, free from warping or other
defects.
 Concrete construction - the tops shall be at least 75 mm thick concrete slabs with a
smooth trowel finish.
All work benches shall be sturdy and the upper surface shall be 920 mm above floor level.
Stools of a suitable height for use at the work benches shall be provided.

The laboratory building shall be provided with piped potable water at a constant head of not
less than 3 m at the taps. Storage capacity in respect of the laboratory water supply shall not
be less than 700 litres.
All rooms shall be provided with electric fluorescent strip lighting of a minimum power rating of
120 W in the laboratory offices and 360 W in the laboratory working area. An adequate number
of 15 ampere 220 Volt electricity plug points shall be provided to the approval of the Engineer.
A 380 Volt 3-phase electric power supply shall be provided as required depending on the
equipment being provided and used in the laboratory. Power points in oven rooms shall be
1.2m above floor level.
The Contractor shall install one telephone line to the laboratory offices as an extension to the
telephone exchange located in the Engineer's office building.
The laboratory shall be provided with exhaust fans located in places susceptible to dangerous
fumes and gases (eg where bitumen extraction tests are carried out). The exhaust fans shall
operate noiselessly and shall have a capacity of at least 0.15 KW each.
Wash basins shall be either of stainless steel or pre-cast ceramic with an area of at least 0.3m²
and minimum depth of 0.3m. They shall be provided with swan neck type laboratory taps and
drain pipes.
All laboratory fittings, furniture and equipment shall be new and shall be maintained in full
working condition throughout the Contract period. Sufficient consumable items shall be supplied
with the equipment and shall be replenished when requested by the Engineer. The tendered
amounts shall include the costs for calibration, maintenance and replacement of any of the
fittings, furniture, equipment; and consumables throughout the Contract period.
The Site laboratory, excluding the laboratory offices, shall be equipped with the fittings, furniture
and equipment shown on the drawings or specified in Tables 1409/3 a, b, c or d; and 1409/4 of
these specifications. The fittings, furniture and equipment required for the offices in the laboratory
building are specified with those of the office building in Table 1409/1 and 1409/2 of these
specifications. Substitution of type may be made only upon approval of the Engineer.
e) Areas around Offices
Unless otherwise approved by the Engineer, access roads of at least 5 m width shall be
provided around the Engineer’s office and laboratory buildings. They shall be surfaced with
compacted gravel of 150 mm minimum thickness, well-drained and kept trafficable at all times.
Culverts shall be constructed where required.
The access and other roads in the vicinity of the Engineer's office and laboratory buildings shall
be kept free from mud and dust by using crushed stone, dust palliatives, suitable dust-laying
oils, bituminous surfacing or by any other approved means.
Concrete paving slabs shall be provided to ensure convenient access between all buildings and
car ports.
f) Communication System for the Engineer

The Contractor shall supply basic mobile telephones in areas of good mobile network
coverage, and/or shall install and maintain a suitable VHF radio communication system for the
sole use of the Engineer. The system shall provide communication between the mobile
personnel, Engineer’s vehicles and Contractor’s and Engineer’s offices covering the whole Site.
The numbers and locations of such devices shall be as described in the Contract.

The systems and equipment shall conform to the following minimum requirements:
 VHF Repeater System providing full Site coverage and comprising:

o A frequency range VHF (136 to 174 MHz);
o Output power of 50 watt;
o Receiver sensitivity 118dBm with 12 SINAD;
o The duplexer frequency range 136 to 174 MHz;
o Continuous power input 80 watt;
o Dipole antenna 6 dB;
o 100 watt solar panel with 30 Amp/ 12 Volt charge regulator.
 VHF Base Station installed at a location directed by the Engineer:
o Number of Channel minimum 16;
o Power supply 220 Input AC voltage and output 13 DC/ 25 Amp;
o Dipole antenna 6 dB;
o Desk-top microphone
 VHF Mobile Stations installed on the vehicles as described in the Contract:
o Number of Channel minimum 16;
o Mobile Antenna with rack mount;
o Palm microphone.
 VHF Hand-held radio for communication from any location on the Site to the site
offices:
o Number of channel 16;
o Single unit charger;
o Rechargeable battery.
The Contractor shall make provision in the rates for the following:
 Compliance with all relevant Government regulations;
 Maintenance of the system;
 Dismantling and removing the system on completion of the contract;
 An equivalent replacement system if the system is out of service for more than three (3)
days.

1404 Housing Accommodation for the Engineer
a) General
The Contractor shall provide, erect, furnish, equip and maintain for the duration of the Contract
period, any or all of the following housing accommodation. The type of facility and the numbers
required are shown in the Bill of Quantities.
Houses for the Engineer shall be:
(i) Type A houses

With 2 bedrooms, living and dining area, a kitchen and bathroom (having a toilet, a wash basin,
shower and/or bath and a mirror). The built up area shall have the minimum floor area indicated
in Table 1409/7 (a).
(ii) Type B houses

With 1 bedroom, living/dining area, and a bathroom (having a toilet, a wash basin, shower and
a mirror). The built up area shall have the minimum floor area indicated in Table 1409/7 (b).
(iii) Type C houses

Multiple bedrooms, common toilet and bathroom for two rooms (The toilet and bathroom shall
be separate having a toilet, a wash basin, shower and a mirror). The built up area shall have
the required floor area indicated in Table 1409/7 (c).
(iv) Type D house (Mess Hall)

Kitchen, dining room, lounge, store, separate Ladies and Gents toilets and lobby. The built up
area shall have the required floor area indicated in Table 1409/7 (d), unless otherwise specified.
b) Description
The buildings shall be constructed with approved prefabricated elements, hollow blocks or
other approved materials as shown in the Contract. The construction material to be used shall
be strong and durable.
The buildings shall be constructed at a location to be approved by the Engineer and shall
conform to current building and architectural practice in Ethiopia for good quality buildings, and
as approved by the Engineer. Furnishings and equipment shall be as approved by the Engineer
and have the following minimum requirements:
 The buildings shall have air-conditioning units if specified in the Contract as described
in Clause 1403 (b). The units shall be electrically operated, thermostatically controlled
with centralised heating/cooling air conditioning system designed to maintain the
temperature 23 to 27ºC with 50% relative humidity maintained during air conditioning.
 The equipment for the Engineer’s houses shall include, but not be limited to, those
items indicated in Table 1409/8, which shall be provided to the satisfaction of the
Engineer.
 The facilities shall be fully wired and connected to a 220/250-volt AC power source,
with at least four (4) power points in each room and five (5) points in the kitchen.
 The furniture and equipment shall be supplied new.
 All buildings/facilities shall have hot and cold running water.
 Where the water supply is not connected to the water main, an external elevated cold
water storage tank with a capacity of 5000 litres shall be provided in order to obtain a

minimum head of 3 metres of water at the taps, together with the pipes leading to the
supply tank.
 Floors shall be concrete covered with suitable carpeting, vinyl tiles or other approved
floor covering.
 The living quarters shall have a clear height from floor to ceiling of 2.7 m as a minimum.
 The total area of windows shall be at least 20% of the exterior wall area and all
windows shall be of an approved type that open and close readily. All windows shall be
provided with insect screens and suitable curtains.
 Each facility after erection/construction shall be properly painted inside and outside with
an approved paint and the paintwork shall be maintained by the Contractor during the
Contract period.
 The entire facilities of the Engineer shall be surrounded with a compound wall or a 2.0
m high chain link fence topped with barbed wire overhang and with a 5m wide gate
secured with a padlock and chain.
 Suitable gravel roads with a minimum width of 5m shall be provided to connect all the
facilities. Roads shall have adequate illumination with overhead lights.
 The Contractor shall provide a day watchman/gardener and night watchman for the
Engineer’s Facilities.
 Except where provided otherwise, the land and accommodation shall be available for
the exclusive use of the Engineer’s personnel for the period of the Contract to the end
of the maintenance period.
c) Maintenance
The Contractor shall arrange to maintain the residential accommodation until the Defects
Liability Certificate for the complete Works is issued. Maintenance includes but is not limited to:
 Attending to repairs to various parts of the building, fittings and equipment;

 Repairs to the connecting services as and when necessary;
 Annual internal and external painting with periodic treatment of wood and steel work;
 Replacement of broken windows/doors;
 Maintenance of internal roads; and
 Other repairs as directed by the Engineer.
The Contractor shall also provide an uninterrupted supply of electricity and water for the
facilities. In case of the loss or interruption to the supply of mains water, electricity or gas, the
Contractor shall make suitable arrangements for the provision of alternative supply.
If the Contractor fails to maintain the residential accommodation, access roads and parking
areas and to provide the services specified, after due warning by the Engineer, the Engineer
may withhold all or part of the monthly payments due under Pay Item 14.04(b).
1405 Services
a) Sanitary arrangements
The Contractor shall be responsible for the provision and maintenance of all sanitary services
necessary to keep latrines in a clean, neat and hygienic condition. When no municipal
sewerage treatment is available, the Contractor shall provide the necessary septic tanks for all

latrine sizes and capacity, as approved by the Engineer. Waste water and septic tank effluent
shall be taken into properly designed French drains.
Where the construction of septic tanks or waste-borne sewerage is, in the opinion of the
Engineer, impractical, the Contractor shall construct conservancy tanks and arrange for the
removal and disposal of the sewerage.
The Contractor shall also provide for the removal of all rubbish.
b) Water, electricity, gas and other chemicals

The Contractor shall provide a constant supply of clean potable water suitable for human
consumption as well as the necessary electric power at 220/250 volts to the Engineer’s
housing, offices and laboratory. The power source shall be suitable for domestic, office and
laboratory use with an anticipated large variance in load factor. Three- phase power shall be
supplied at a nominal voltage of 400/231 volts and a nominal frequency of 50 HZ. The source of
power shall be either from a recognized power-supply authority or by an on-site generator
supplied by the Contractor.
The electrical load shall be determined by an appropriate diversity factor being applied to the
sum of the connected load, due allowance being made for the starting load, efficiency and
power factor of motors, or shall be estimated on the basis of 1,2 kVA per m² of laboratory floor
area (three phase) and 0,35 kVA per m² of office area. Allowance shall be made for a spare
capacity of 15% with a minimum of 15 kVA. A detailed load estimate shall be submitted to the
Engineer for approval prior to any final arrangements being made for a source of power.
In the event of electricity being generated by the Contractor, the motor-alternator shall be
suitable to maintain the voltage so that it will not deviate by more than ± 5% from the nominal
voltage and to maintain the frequency so that it will not deviate from the nominal frequency by
more than ± 2 Hz over the entire load range from 0% to 100% of full load; and also in the event
of switching on and off all normal loads connected to the supply. Power shall be available to the
accommodation, offices and the laboratory for 24 hours per day.
Power shall be distributed by means of enclosed distribution boards with adequate weather and
tamper protection, suitably rated circuit breakers, earth-leakage units or fuses, and by means of
adequately sized underground cables and earth conductors. Sizing of cables and rating of
protective and control devices shall take into account the load and fault currents that can occur
on the system.
The reticulation network and the wiring installation of all buildings and structures shall be
installed and maintained to ensure absolute safety and high standard of reliability, with
particular reference to the earthling installation and safety and protective devices. The
installations shall comply with the requirements of Ethiopian Electricity and Power Corporation.
The Contractor shall at all times maintain the power supply, the distribution network and the
wiring installation of all buildings and structures at the highest standard of safety and usability.
The Contractor shall also supply liquid petroleum gas for the burners used in the laboratory and
office and any other chemicals necessary to undertake tests in the laboratory as required by the
Engineer.

c) Maintenance
The Contractor shall provide all labour, equipment and materials which may be necessary for
keeping all the buildings in a neat and clean condition, and any repairs shall be made
immediately at the request of the Engineer.
If the Contractor fails to maintain the services specified, after due warning by the Engineer, the
Engineer may withhold all or part of the monthly payments due under Pay Item 14.04(b).
d) Assistance to the Engineer

The Contractor shall provide at all times during the period of the Contract, for the exclusive use
of the Engineer, all such workmen and junior support workers as the Engineer may deem to be
necessary for the carrying out of his duties in connection with the contract. This would include,
but not be limited to, drivers, chainmen, labourers, office support workers, cleaners, watchmen
and security personnel. (Also see Clause 1407)
Such staff shall be approved by the Engineer and shall be responsible to him, although they will
be in the employ of the Contractor. The Contractor shall include in his rates in the Bill of
Quantities, the cost of all attendance upon the Engineer and his staff. No separate payment
shall be made in respect of assistance to the Engineer, except where a specific item is provided
for in the Bill of Quantities. Otherwise, full compensation for assistance to the Engineer shall be
deemed to be included in the tendered rates for the various items in the Bills of Quantities.
e) Safety and Emergency Equipment

The Contractor shall supply to the Engineer and his staff, emergency equipment, safety clothing
(including overalls and reflective jackets), helmets, safety boots and tools as required. No
separate payment shall be made in respect of emergency equipment and safety facilities,
except where a specific item is provided for in the Bill of Quantities. Otherwise, full
compensation for the supply of emergency equipment and safety facilities shall be deemed to
be included in the tendered rates for the various items in the Bills of Quantities for offices and
laboratory.
1406 Vehicles
a) General
The Contractor shall provide vehicles for the sole use of the Engineer and his staff. The
vehicles shall be new and must be comprehensively insured to cover all drivers and
passengers.
The Contractor, at his own cost, shall provide a replacement for any vehicle by a similar new
vehicle after completion of 150,000 km if, in the opinion of the Engineer, such vehicle cannot be
maintained in a satisfactory condition.
The Contractor shall provide, where directed by the Engineer, experienced drivers, who shall
be available to the Engineer at all times.
The Contractor shall provide the vehicles with fuel and lubricants as required and shall service,
maintain and repair the vehicles so as to be in a reliable and roadworthy condition at all times.
b) Types of Vehicles
The following types of vehicles shall be supplied by the Contractor for the sole use of the
Engineer.

(i) Vehicle Type A

On/off-road 4WD station wagon; hard top; semi LWB or LWB; 5-doors; 3.7 – 4.3 litre turbo-
diesel engine; LHD power steering; seating capacity for 8.
(ii) Vehicle Type B

4WD Pick-up; Double cabin; 4-doors; LWB; 2.5 – 3.0 litre diesel engine (preferably
turbocharged); LHD power steering; seating capacity for 5.
(iii) Vehicle Type C

4WD Pick-up; Single cabin; 2-doors; LWB; 2.5 – 3.0 litre diesel engine (preferably
turbocharged); LHD power steering; seating capacity for 3.
All vehicles shall be supplied according to the Contract and shall be available to the Engineer
within 120 days of the date of commencement of the Works or any other days as stated in the
Contract; or, in default, the Contractor shall continue to provide temporary vehicles at the
Contractor’s own cost. This is without prejudicing the Engineer’s right to take other contractual
actions.
The Contractor shall be responsible for replacement whether temporary or permanent of any
vehicle through repair or accident where such vehicle is unavailable to the Engineer for a
period of more than 24 hours.
1407 Attendance
The Contractor shall provide the Engineer with, and maintain continuity of, operatives equal to
the tasks and capable of performing the functions described in the Contract. Survey operatives
shall be capable of assisting Surveyors in manual tasks. Laboratory assistants shall be capable
of assisting the Engineer’s laboratory staff in manual tasks. Drivers provided for the Engineer’s
site vehicles shall have a valid driving license and driving experience suitable for the vehicles
supplied. Cleaning staff shall be capable of carrying out duties to the satisfaction of the
Engineer.
The Contractor shall provide soap and towels in the offices and laboratories of the Engineer;
the services of cleaners and sanitary staff, together with cleaning equipment; and day and night
watchmen/security personnel.
The Contractor shall provide all assistance to the manual labourers assigned to the Engineer.
The assistance shall include, but not be limited to, all tools and protective clothing, wooden
pegs, iron picks and pickets, water, cement and aggregate for concreting, transport for
labourers and materials, as may be required by the Engineer and his staff for checking, setting
out, surveying, measuring or testing the work.
The Contractor shall include in his rates in the Bill of Quantities, the cost of all attendance upon
the Engineer and his staff. No other payment shall be made in respect of attendance, except
where a specific item is provided for in the Bill of Quantities.
1408 Temporary Facilities and Vehicles for the Engineer

The Contractor shall, between the date of commencement of the works and the handing over of
all the site facilities to the Engineer (ie 120 days unless stated otherwise) provide to the
Engineer temporary site offices, laboratory and housing which have been fully fitted, furnished
and equipped to the approval of the Engineer; and suitable vehicles, including all operating
costs.

In the event that any permanent facilities for the Engineer and his staff are not made available
within 120 days of the commencement of the works through default by the Contractor, the
Contractor shall, at his own cost, continue to provide the individual temporary facilities by
increasing the quantity of temporary facilities equal to the quantity of permanent Engineers’
facilities as indicated on BoQ (both for provision and maintenance) without prejudicing the
Engineer’s right to take additional contractual measures in order to rectify the situation. Such
temporary offices may, at the Engineer’s discretion, be the provision of suitable rented office
facility for the purpose and shall include full running cost.

1409 Tables
The options set out in the following Tables are itemised under three categories of Large Scale,
Medium Scale and Small Scale Works contracts. The options to be applied and detailed requirements
are set out in the Particular Specifications. The three options are:
Option 1: Large Scale Projects
Option 2: Medium Scale Projects
Option 3: Small Scale Projects
Laboratory equipment for gravel surfaced roads are only shown for options 2 and 3 in
Table 1409/3 (c).
Table 1409/1: Office Furniture
Quantity
Item Description
Option 1 Option 2 Option 3
Desks shall have a surface area of at least 1.5 m²

with six (6) drawers of which two (2) shall be
1 2 1 1
lockable with two (2) keys per lock. This item
includes an executive chair (one per desk)
Desks shall have a surface area of at least 1.2 m²

with three (3) drawers of which at least 1 shall be
2 10 5 2
lockable with two (2) keys. This item includes
executive chair (one per desk).
Steel general purpose cabinets shall have at least

3 1.5 m² shelf area and a volume of 0.70 m³. Each 3 2 1
cabinet shall have a lock with two (2) keys
Steel filing cabinets shall each be fitted with four

(4) drawers on runners. Each cabinet shall be
4 fitted with a lock and two keys and shall be 1300 3 2 1
mm high, 460 mm wide and 600 mm from front to
back.
Conference table (1.5 m x 0.9 m). Each table shall

5 be square edged so that adjoining tables can form 3 3 -
a conference table.
Conference room chairs which shall be padded,

6 12 6 -
sturdy and of the swivel type.
Black/White Board (with writing/cleaning

7 1 1 -
equipment)
8 Table for computer and printer 2 1 -
9 Guest Chairs (sturdy and comfortable) 15 12 6

Table 1409/2: Office Supplies and Equipment
Quantity
Item Description
1 Waste paper basket 12 6 3
2 Staplers 12 6 3
3 Paper punch 12 6 3
4 Heavy duty paper punch 2 1 1
5 Heavy duty stapler 2 1 1
6 Steel straight edge 1m. 1 1 1
7 Filing tray (set of 3) 12 6 3
Digital Camera as specified in the Particular

8 2 1 1
Specifications
9 Electric kettle 3 2 1
10 Electric refrigerator, 100 litre capacity 1 1 1
11 Tea Set 2 1 1
12 Field book 4 2 1
Total Station surveying instrument including

13 2 1 1
2 single prism targets and tripods.
14 Level (automatic) 2 1 1
15 Levelling staff (5m) 6 2 1
16 Ranging rod (2m) 12 6 3
17 Optical square 2 1 1
18 Steel tape 100m. 3 2 1
19 Linen tape 30m 6 3 2
20 Steel pocket tape 12 6 3
21 Cane knives 2 1 1
22 Hammer (5kg) 2 1 1
23 Survey umbrella 2 1 1
24 Rain gauge 1 1 1
25 Thermometer (max/min) 1 1 1
26 First Aid kit 2 1 1
Desktop computers and software having the

27 capacity indicated in the Particular 4 3 2
Specifications

Laser colour printer with carriage for up to

28 A3 paper or as specified in the Particular 2 1 1
Specifications
Photocopier with copy size up to A3,

capable of reducing or enlarging between
29 2 1 1
A3 and A4 or as specified in the Particular
Specifications
30 Heavy Duty Shelving in Stores 6m 4m 2m
Scanner as specified in the Particular

31 2 1 1
Specifications
Plotter as specified in the Particular

32 1 - -
Specifications
33 Water closet 2 1 1
34 Hand basin (complete) 2 1 1
35 Kitchen Sink Unit 1 1 1
36 Fire extinguishers 3 2 1
37 Telephone extensions 11 5 2
Full international telephone and Internet

38 1 1 1
connection
39 Laptop computer 3 2 1
40 A4 size laser printer (black & white) 4 3 1
Facsimile transmitting machine (approved

41 1 1 1
by the Engineer)
Handheld GPS or equivalent as specified in

42 2 1 1
the Particular Specifications

Table 1409/3: Laboratory Equipment
The Contractor shall provide the site laboratory included in the Contract for the exclusive use of the
supervision team with equipment at least equal to the lists in Tables 1409/3 (a), (b), (c) and (d).
Substitution of type may be made only upon approval of the Engineer.
(a) List of Laboratory Equipment for Asphalt Concrete Roads
Quantity
Item Description

General
Set of ISO 3310-1 stainless steel sieves diameter 300 mm

including, but not limited to, the following aperture sizes:
75.0 mm; 63.0 mm; 50.0 mm; 37.5 mm; 26.5 mm;
1 3 sets 2 sets 1 set
19.0 mm; 16.0 mm; 14.0 mm; 12.5 mm; 10.0 mm;
9.5 mm; 6.3 mm; 4.75 mm; 4.0 mm, including lid and
receiver.

2 2.0 mm; 1.70 mm; 1.00 mm; 600 micron; 500 micron; 3 sets 2 sets 1 set
425 micron; 300 micron; 150 micron; 125 micron;
75 micron, including lid and receiver.
3 Sieve brush, double-ended nylon 4 2 2
200 mm diameter x 200 mm deep washing sieve with 75

4 2 1 1
micron mesh
5 Sieve shaker, gyratory for 200 and 300 mm dia. sieves 1 1 1
Electronic weighing scale/balance, 3.5 kg capacity, 0.1g

6 4 2 1
accuracy, calibrated with underwater weighing capability
Electronic weighing scale/balance, 0.25 kg capacity, 0.01

7 2 1 1
g accuracy and calibrated
Weighing scale/balance, 25 kg capacity, 1 g accuracy and

8 2 1 1
calibrated
Drying oven, 225 litre capacity, fan circulated,

9 thermostatically controlled, 220-240v, 50/60Hz, single 3 2 1
phase with 3 shelves and dial thermometer
Warm air drying unit, 100ºC max, 220-240v, 50/60Hz,

10 1 - -
single phase
Hotplate, 200mm diameter, 220-240v, 50/60Hz, single

11 4 2 1
phase with Simerstat
Hotplate, 300 x 500 mm, digital temperature indicator 0-

12 1 - -
300 ºC, 220-240v, 50/60Hz, single phase
13 Glass plates 0.5 x 0.5 x 0.05 m 2 1 1
14 Set of Spatulas, 100mm blade, 150mm blade and 200mm 6 sets 3 sets 2 sets

Quantity
Item Description
blade
15 Chattaway spatula, 125mm blade 3 2 1
16 Moisture content tins 100 60 40
17 Sample trays 306 x 306 x 38 mm 10 5 3
Sample splitter, large capacity, 100mm down, 28.3 litre

20 1 - -
hopper capacity
21 Riffle box, steel, 10 mm, 12 slots 2 1 1
24 Thermometer, min/max, double scale, -20 to +50 ºC 4 2 1
25 Thermometer, laboratory mercury, 0 to 110 ºC 4 2 2
26 Thermometer, surface, 64 mm diameter, dial 0 to 160 ºC 1 1 1
27 Thermometer, electronic potable digital, 0 to 300 ºC 2 1 1
28 Thermometer, digital probe, 50 – 300 ºC 2 1 1
29 Timing Device 3 2 1
30 Gloves – heat resistant As required
31 Gloves – water and chemical resistant As required
32 Glass beakers, 100 mm, squat form with spout 6 4 2
35 Measuring cylinder, 100 x 1 ml, soda glass 2 1 1
39 Measuring cylinder, 100 x 1 ml, plastic 2 1 1
43 Evaporating dish, 100 mm dia x 40 mm depth 3 2 1

Quantity
Item Description
46 Water test kit for chlorides, alkalinity and hardness 1 1 1
47 Pocket Calculator, Scientific 12 7 3
48 Right-angled Triangles type 30º and 45º - 300 mm 3 sets 2 sets 1 set
50 Metric Ruler 12 7 3
51 Large Log Book 12 7 3
52 Pencil Sharpener 12 7 3
53 Protractor, 150 mm 3 2 1
54 Assorted French Curve Set 1 1 1
55 Claw hammer 3 2 1
56 Hammer 1 kg 1 1 1
57 Hammer 2.5 kg 1 1 1
58 Tool kit, multipurpose with box 3 2 1
59 A4 Clip Board As required
60 Cross Section paper (Graphiquest Canson) - Pad 1 1 1
61 Slide callipers 1 1 1
62 Micro metre (mm reading) 1 1 1
63 Vacuum Pump 1 1 1
64 Wash bottles 10 6 4
65 Pipettes, 5 ml, 10 ml, 20 ml, 50 ml and 100 ml 3 sets 2 sets 1 set
66 Brushes, paint brush type at 100 mm, 50 mm and 25 mm 3 sets 2 sets 1 set
67 Polyethylene bags 40 lt. As required
70 Rubber mallet 2 no. 1 1
71 Trowel 5 no. 3 1
72 Pycnometer set suitable for SG and relative density

1 set 1 set 1 set
measurement of soils and aggregates to ASTM D854-98
73 Water baths, thermostatically controlled capable of

2 1 1
maintaining constant temperatures up to 60ºC
74 Scoops, large for aggregate 6 4 2
75 Scoops, medium for sand 6 4 2

Quantity
Item Description
Bulk Density measures, steel with capacity, 3 litre, 7 litre,

76 10 litre, 15 litre and 30 litre, all with handles except for 3 1 set 1 set 1 set
litre container.
77 Field scale 2.6 kg 3 2 1
78 Field scale 20 kg 3 2 1
79 Lubricating oil As required
Soil Sampling
80 Soil colour chart 1 1 1
81 Soil auger head, 100mm dia, heavy duty steel 1 1 -
82 Soil auger head, 150mm dia, heavy duty steel 1 - -
83 Soil auger head, Dutch type, 50 mm, heavy duty steel 1 - -
84 Gravel auger head, 150mm dia, heavy duty steel 1 1 -
Extension rods, 27mm dia, 1m length for use with auger

85 10 10 -
heads, heavy duty steel
86 Stillson wrench, size 14 2 1 -
87 Handle and T-piece for hand boring, heavy duty steel 2 1 -
88 Jarring link for driving sample tubes 2 1 -
89 Spiral auger, 40mm dia, one piece, heavy duty 1 1 -
90 Sample tube, 38mm dia x 2 30mm long with end caps 10 10 -
91 Adaptor for extension rods 2 1 -
Rubber headed pestle and Porcelain mortar suitable for

92 1 1 -
sample reduction
Sample extruder, 38mm dia, hand-operated, hydraulic

93 complete with trimming knife, 38mm split former and 1 1 -
cutting tool
Sample extruder for 100mm (including Marshall Asphalt

94 specimens) and 150mm samples including frame and 1 1 1
hydraulic jack
Moulds, core cutter and collar for 100mm dia and 150 mm
dia samples for in-situ dry density and CBR
95 10 6 -
determinations including driving dolly to fit the core cutter
and driving rammer
Melting pot, 4 litre capacity, 50 - 300ºC range suitable for

96 1 1 -
melting paraffin wax or capping compound
Atterberg Limits

Quantity
Item Description
Liquid limit apparatus to ASTM D423-66 with hard rubber

97 base of shore D value 85-95 @ 23ºC, grooving tool and 2 1 1
calibrating plate
98 Ground glass plate, 250mm x 250mm 2 1 1
Shrinkage troughs for bar linear shrinkage tests to SANS

99 3001-GR10, 25mm x 25mm x 150mm long with paint 10 6 4
brush, spatula and dividers with a millimetre scale
Standard Laboratory Compaction
100 Compaction hammer, 4.536 kg, drop 457.2mm, 50.8 mm

3 2 1
dia.
Compaction hammer, 2.495 kg, drop 304.8mm, 50.8 mm

101 3 2 1
dia
Moulds, 152.4 mm dia x 152.4 mm high, with detachable

102 collar and base with a 25.4 mm spacer plate to give an 10 6 4
effective mould depth of 127mm
103 Steel straight edge, 300mm long with a bevelled edge 4 2 1
Moulds, 101.6 mm dia x 116.43 mm high with detachable

104 6 4 2
collar and base plate
Laboratory CBR test
A hydraulic compression testing machine with a capacity

of at least 55kN load recordable to the nearest 50N and
105 capable of applying load at a rate of strain of 1.27 1 1 1
mm/min, including a metal circular piston of 50 mm dia
and weighing 4.536kg

collar and base with a 25.4 mm spacer plate to give an
106 10 6 4
effective mould depth of 127mm and perforated soaking
base plates (also see item 87)
107 Annular 4.536 kg surcharge weights used during soaking 10 6 4
108 Annular 5.56 kg surcharge weights for use during

10 6 4
penetration
109 1.024 kg perforated plates with adjustable stems 10 6 4
110 A tripod for measuring swell 10 6 4
Dial gauges or equivalent reading 0.01 mm with a range

111 12 8 6
of 25 mm

Quantity
Item Description
Dial gauge or equivalent with 0.127 mm divisions, range

112 2 2 2
25 mm and 1.27 mm per revolution
113 Filter paper (CBR) in packs of 100 10 6 4
114 Copper or brass gauze discs of 30 mesh and 170mm dia. 10 6 4
Galvanised iron mixing bath , 450 mm x 650 mm x 200

115 1 1 1
mm deep
116 Soaking bath, 300 mm deep 1 1 1
Dynamic Cone Penetrometer (DCP)
Dynamic Cone Penetrometer, complete with 10 No

117 threaded extension rods, 20 No. spare cones and carrying 2 sets 1 set 1 set
case
118 DCP software package 1 1 1
Dry Density – Sand Replacement
Sand density device/funnel/bottle with accessories

119 including a density ring with a 152 mm dia hole for ASTM 2 1 1
D1556 or AASHTO T296 T297
120 Sand suitable for calibration As required
121 Calibration sieves , 0.425 mm and 0.25 mm 1 set 1 set 1 set
122 Basin 400 mm dia 1 1 1
Cylindrical calibration container, internal diameter and

123 1 1 1
height 152 mm
124 Glass plate, 180 mm x 180 mm x 7 mm thick 1 1 1
125 Hammer, 2 kg 2 1 1
126 Chisel, cold steel 25 mm 2 1 1
127 Tablespoons 4 2 2
128 Containers, tins of 5 litre capacity 10 6 4
Density and Moisture Content - Nuclear Method
Particular Specification. Only to be provided on approval

129 - - -
by the Employer
Aggregate Testing
Aggregate Impact Value Device to BS 812, including

130 1 1 1
cylinder and tamping rod

Quantity
Item Description
Compression machine, hydraulic, capable of applying a

load of 400 kN at a uniform rate so that the load can be
reached in 10 min suitable for Aggregate Crushing Value
(ACV) and 10% Fine Aggregate Crushing Test (10%
131 1 1 -
FACT) testing, including and open-ended steel cylinder of
150 mm dia with plunger and base plate, a cylindrical
measure of 155 mm x 180 mm deep and metal tamping
rod 16 mm dia 500 mm long with a hemispherical end.
Flakiness index gauge of metal 1.6 mm thick having

132 rectangular slots for each size fraction of aggregate to be 1 1 1
tested
133 Average Least Dimension (ALD) Device 1 - -
134 Los Angeles Abrasion machine including charges 1 - -
135 Durability Mill, including charges 1 - -
Concrete Testing

load of 2000 kN at a uniform rate.
136 (NB One (1)universal compression machine could be 1 1 1
considered for aggregate testing, concrete cube
testing and CBR testing on approval by the Engineer)
Concrete test cube moulds 150mm x 150mm x 150mm,

137 24. 12 6
including tamping bars/rods
Curing tanks, thermostatically controlled, minimum 600

138 4 2 1
mm square and 500 mm deep
139 Coring device with the capability of taking 100mm and

150mm diameter cores from cementitious and bituminous 1 - -
materials
140 Cylinder moulds 100mm diameter x 200mm long for ITS

6 3 -
and UCS testing

6 3 -
and UCS testing
142 Slump test device, cone and tamping rod 2 1 1
143 Concrete Test Hammer (Schmidt Hammer or similar) 1 - -
144 Straight edge 3 2 1
145 Steel ruler 3 2 1
Sand Equivalent Test
146 Sand Equivalent Test Set 1 1 1
147 Sand Equivalent Stock Solution (1 kg) 10. 10 10

Quantity
Item Description
Asphalt Concrete Testing
148 Bitumen extraction machine, centrifuge type, 3000gm

capacity, electrically operated having Dimmerstat for
1 1 1
controlling speed from 2400 to 3600rpm with pack of
Filter Paper (50 Circles)
149 Beakers for above 6 no. 6 6
150 Solvent as required
151 BI-metal thermometer (0 - 300 C) 100 and 300 mm 6 no. 4 2
152 Electrical thermometer (0 -300 C) 2 no. 1 1
153 0.10 m core drilling machine with 12 core drills 1 no. - -
Sampling and Testing Bituminous Materials
154 0.5 lt. Sample Can 24 12 6
155 0.5 lt. Small Mouth Can 24 12 6
156 Bitumen Penetrometer with 5 needles and sample

1 1 1
holders
157 Softening point devices including heating system 1 1 1
158 Brookfield viscometer and associated apparatus 1 - -
159 Rolling Thin Film Oven and associated apparatus 1 - -
Marshall Test
160 Bench Mixer, 5 lt capacity with bowl heater and whisk 1 1 1
161 Stirring Rod 2 1 1
Automatic Marshall compaction machine with hammer

162 2 1 1
and pedestal
163 Marshall compaction moulds complete 12 6 4
164 Filter paper for moulds As required
Compression Machine, hydraulic, 50 kN capacity with

165 calibrated load rings, flow and stability gauges and 1 1 1
stability breaking head
166 Sample ejecting device 1 1 1
167 Thermostatically controlled Standard Water Bath to 60C 1 1 1
Balance, water container and basket for bulk relative

168 density and void contents of compacted bitumen 1 1 1
mixtures

Quantity
Item Description
SuperPave equipment or similar for design and performance testing of Asphalt mixes
Particular Specifications. Only to be provided on

169 - - -
approval by the Engineer.

(b) List of Laboratory Equipment for Surface Sealed roads
Quantity
Item Description
General

75.0 mm; 63.0 mm; 50.0 mm; 37.5 mm; 26.5 mm;
1 3 sets 2 set 1 set
19.0 mm; 16.0 mm; 14.0 mm; 12.5 mm; 10.0 mm;
receiver.

2 2.0 mm; 1.70 mm; 1.00 mm; 600 micron; 500 micron; 3 sets 2 set 1 set

4 2 1 1
micron mesh
Electronic weighing scale/balance, 3.5 kg capacity, 0.1 g

6 4 2 1

7 2 1 1

8 2 1 1
calibrated


10 1 - -
single phase

11 4 2 1

12 1 - -
13 Glass plates 0.5 x 0.5 x 0.05 m 2 1 1
Set of Spatulas, 100mm blade, 150mm blade and 200mm

14 6 sets 3 sets 2 sets
blade

Quantity
Item Description

20 1 - -
hopper capacity
26 Thermometer, surface, 64 mm diameter, dial 0 to 160 ºC 1 1 1
28 Thermometer, digital probe, 50 – 300 ºC 2 1 1

Quantity
Item Description
57 Hammer 2.5 kg 1 1 1
61 Slide callipers 1 1 1
65 Pipettes, 5 ml, 10 ml, 20ml, 50 ml and 100 ml 3 sets 2 sets 1 set
71 Trowel 5 no. 3 1

1 set 1 set 1 set

2 1 1

76 1 set 1 set 1 set
10 litre, 15 litre and 30 litre, all with handles except for 3

Quantity
Item Description
litre container.
Soil Sampling
80 Soil colour chart 1 1 1
81 Soil auger head, 100mm dia, heavy duty steel 1 1 -
82 Soil auger head, 150mm dia, heavy duty steel 1 - -
83 Soil auger head, Dutch type, 50 mm, heavy duty steel 1 - -
84 Gravel auger head, 150mm dia, heavy duty steel 1 1 -
Extension rods, 27mm dia, 1m length for use with auger

85 10 10 -
86 Stillson wrench, size 14 2 1 -
87 Handle and T-piece for hand boring, heavy duty steel 2 1 -
88 Jarring link for driving sample tubes 2 1 -
89 Spiral auger, 40mm dia, one piece, heavy duty 1 1 -
90 Sample tube, 38mm dia x 2 30mm long with end caps 10 10 -
91 Adaptor for extension rods 2 1 -
Rubber headed pestle and Porcelain mortar suitable for

92 1 1 -
sample reduction

93 complete with trimming knife, 38mm split former and 1 1 -
cutting tool
Sample extruder for 100mm and 150mm samples

94 1 1 1
including frame and hydraulic jack
dia samples for in-situ dry density and CBR
95 10 6 -
and driving rammer
Melting pot, 4 litre capacity, 50 - 300ºC range suitable for

96 1 1 -

Quantity
Item Description
Atterberg Limits

97 base of shore D value 85-95 @ 23ºC, grooving tool and 2 1 1
calibrating plate
98 Ground glass plate, 250mm x 250mm 2 1 1

99 3001-GR10, 25mm x 25mm x 150mm long with paint 10 6 4
100 Compaction hammer, 4.536 kg, drop 457.2mm, 50.8 mm

3 2 1
dia.
Compaction hammer, 2.495 kg, drop 304.8mm, 50.8 mm

101 3 2 1
dia

102 collar and base with a 25.4 mm spacer plate to give an 10 6 4
103 Steel straight edge, 300mm long with a bevelled edge 4 2 1
Moulds, 101.6 mm dia x 116.43 mm high with detachable

104 6 4 2
Laboratory CBR test

105 capable of applying load at a rate of strain of 1.27 1 1 1

collar and base with a 25.4 mm spacer plate to give an
106 10 6 4
107 Annular 4.536 kg surcharge weights used during soaking 10 6 4
108 Annular 5.56 kg surcharge weights for use during

10 6 4
penetration
109 1.024 kg perforated plates with adjustable stems 10 6 4
110 A tripod for measuring swell 10 6 4
111 Dial gauges reading 0.01 mm with a range of 25mm 12 8 6
Dial gauge or equivalent with 0.127 mm divisions, range

112 2 2 2

Quantity
Item Description
113 Filter paper (CBR) in packs of 100 10 6 4
114 Copper or brass gauze discs of 30 mesh and 170mm dia. 10 6 4
Galvanised iron mixing bath , 450 mm x 650 mm x 200

115 1 1 1
mm deep
116 Soaking bath, 300 mm deep 1 1 1

case
118 DCP software package 1 1 1

119 including a density ring with a 152 mm dia hole for ASTM 2 1 1
121 Calibration sieves , 0.425 mm and 0.25 mm 1 set 1 set 1 set
122 Basin 400 mm dia 1 1 1
Cylindrical calibration container, internal diameter and

123 1 1 1
height 152 mm
124 Glass plate, 180 mm x 180 mm x 7 mm thick 1 1 1
125 Hammer, 2 kg 2 1 1
126 Chisel, cold steel 25 mm 2 1 1
127 Tablespoons 4 2 2
128 Containers, tins of 5 litre capacity 10 6 4
Particular Specification. Only to be used on approval by

129 - - -
the Employer
Aggregate Testing

130 1 1 1

Quantity
Item Description

reached in 10 mins suitable for Aggregate Crushing Value
131 1 1 1
rod 16 mm dia, 500 mm long with a hemispherical end.

tested
133 Average Least Dimension (ALD) Device 1 1 1
135 Durability Mill, including charges 1 - -
Concrete Testing

load of 2000 kN at a uniform rate

137 24. 12 6

138 4 2 1

150mm diameter cores from cementitious and bituminous 1 1 1
materials

12 6 6
and UCS testing

12 6 6
and UCS testing
143 Concrete Test Hammer (Schmidt Hammer or similar) 1 1 -

Quantity
Item Description
Sampling and Testing Bituminous Materials
148 0.5 lt. Sample Can 24 12 6
149 0.5 lt. Small Mouth Can 24 12 6
150 Bitumen Penetrometer with 5 needles and sample

1 1 1
holders
151 Softening point devices including heating system 1 1 -
152 Brookfield viscometer and associated apparatus 1 - -
153 Rolling Thin Film Oven and associated apparatus 1 - -

(c) List of Laboratory Equipment for Gravel Surfaced Roads
Quantity
Item Description

General
Set of ASTM stainless steel sieves diameter 300 mm

1 75.0 mm; 63.0 mm; 50.0 mm; 37.5 mm; 26.5 mm; - 2 set 1 set
19.0 mm; 16.0 mm; 12.5 mm; 9.5 mm; 6.3 mm; 4.75 mm;
4.0 mm, including lid and receiver.
Set of ASTM stainless steel sieves diameter 200 mm

2 2.0 mm; 1.70 mm; 1.00 mm; 600 micron; 500 micron; - 2 set 1 set
3 Sieve brush, double-ended nylon - 2 2
200 mm diameter x 200 mm deep washing sieve with 75 -

4 1 1
micron mesh
5 Sieve shaker, gyratory for 200 and 300 mm dia. sieves - 1 1
Electronic weighing scale/balance, 3.5 kg capacity, 0.1 g -

6 2 1
Electronic weighing scale/balance, 0.25 kg capacity, -

7 1 1
0.01 g accuracy and calibrated
Weighing scale/balance, 25 kg capacity, 1 g accuracy and -

8 1 1
calibrated

9 thermostatically controlled, 220-240v, 50/60Hz, single - 1 1
Warm air drying unit, 100ºC max, 220-240v, 50/60Hz, -

10 1 -
single phase
Hotplate, 200mm diameter, 220-240v, 50/60Hz, single -

11 1 -
Hotplate, 300 x 500 mm, digital temperature indicator 0- -

12 1 -
13 Glass plates 0.5 x 0.5 x 0.05 m - 1 1
Set of Spatulas, 100mm blade, 150mm blade and 200mm -

14 3 sets 2 sets
blade
15 Chattaway spatula, 125mm blade - 2 1
16 Moisture content tins - 60 40

Quantity
Item Description
17 Sample trays 306 x 306 x 38 mm - 5 3
Sample splitter, large capacity, 100mm down, 28.3 litre -

20 1 -
hopper capacity
21 Riffle box, steel, 10 mm, 12 slots - 1 1
24 Thermometer, min/max, double scale, -20 to +50 ºC - 2 1
25 Thermometer, laboratory mercury, 0 to 110 ºC - 2 2
26 Thermometer, surface, 64 mm diameter, dial 0 to 160 ºC - - -
27 Thermometer, electronic potable digital, 0 to 300 ºC - 1 1
28 Thermometer, digital probe, 50 – 300 ºC - - -
29 Timing Device - 1 1
32 Glass beakers, 100 mm, squat form with spout - 4 2
35 Measuring cylinder, 100 x 1 ml, soda glass - 1 1
39 Measuring cylinder, 100 x 1 ml, plastic - 1 1
43 Evaporating dish, 100 mm dia x 40 mm depth - 2 1
46 Water test kit for chlorides, alkalinity and hardness - 1 1
47 Pocket Calculator, Scientific - 7 3

Quantity
Item Description
48 Right-angled Triangles type 30º and 45º - 300 mm - 2 sets 1 set
49 Right-angled Triangles type 30º and 45º - 150 mm - 2 sets 1 set
50 Metric Ruler - 7 3
51 Large Log Book - 7 3
52 Pencil Sharpener - 7 3
53 Protractor, 150 mm - 2 1
54 Assorted French Curve Set - 1 1
55 Claw hammer - 2 1
56 Hammer 1 kg - 1 1
57 Hammer 2.5 kg - 1 1
58 Tool kit, multipurpose with box - 2 1
60 Cross Section paper (Graphiquest Canson) - Pad - 1 1
61 Slide calipers - 1 1
62 Micro metre (mm reading) - 1 1
63 Vacuum Pump - 1 1
64 Wash bottles - 6 4
65 Pipettes, 5 ml, 10 ml, 20ml, 50 ml and 100 ml - 2 sets 1 set
66 Brushes, paint brush type at 100 mm, 50 mm and 25 mm - 2 sets 1 set
70 Rubber mallet - 1 1
71 Trowel - 3 1
72 Pycnometer set suitable for SG and relative density - 1 set 1 set

73 Water baths, thermostatically controlled capable of - 1 1

74 Scoops, large for aggregate - 4 2
75 Scoops, medium for sand - 4 2
Bulk Density measures, steel with capacity, 3 litre, 7 litre, -

76 1 set 1 set
10 litre, 15 litre and 30 litre, all with handles except for 3

Quantity
Item Description
litre container.
77 Field scale 2.6 kg - 2 1
78 Field scale 20 kg - 2 1
Soil Sampling
80 Soil colour chart - 1 1
81 Soil auger head, 100mm dia, heavy duty steel - 1 -
82 Soil auger head, 150mm dia, heavy duty steel - 1 -
83 Soil auger head, Dutch type, 50 mm, heavy duty steel - 1 -
84 Gravel auger head, 150mm dia, heavy duty steel - 1 -
Extension rods, 27mm dia, 1m length for use with auger -

85 1 -
86 Stillson wrench, size 14 - 1 -
87 Handle and T-piece for hand boring, heavy duty steel - 1 -
88 Jarring link for driving sample tubes - 1 -
89 Spiral auger, 40mm dia, one piece, heavy duty - 1 -
90 Sample tube, 38mm dia x 2 30mm long with end caps - 1 -
91 Adaptor for extension rods - 1 -
Rubber headed pestle and Porcelain mortar suitable for -

92 1 1
sample reduction

93 complete with trimming knife, 38mm split former and - 1 -
cutting tool
Sample extruder for 100mm and 150mm samples -

94 1 1
including frame and hydraulic jack
dia samples for in-situ dry density and CBR -
95 6 -
and driving rammer
Melting pot, 4 litre capacity, 50 - 300ºC range suitable for -

96 1 -

Quantity
Item Description
Atterberg Limits

97 base of shore D value 85-95 @ 23ºC, grooving tool and - 1 1
calibrating plate
98 Ground glass plate, 250mm x 250mm - 1 1

99 3001-GR10, 25mm x 25mm x 150mm long with paint - 6 4
100 Compaction hammer, 4.536 kg, drop 457.2mm, 50.8 mm - 2 1

dia.
Compaction hammer, 2.495 kg, drop 304.8mm, 50.8 mm -

101 2 1
dia

102 collar and base with a 25.4 mm spacer plate to give an - 6 4
103 Steel straight edge, 300mm long with a bevelled edge - 2 1
Moulds, 101.6 mm dia x 116.43 mm high with detachable -

104 4 2
Laboratory CBR test

105 capable of applying load at a rate of strain of 1.27 - 1 1

collar and base with a 25.4 mm spacer plate to give an -
106 6 4
107 Annular 4.536 kg surcharge weights used during soaking - 6 4
108 Annular 5.56 kg surcharge weights for use during - 6 4

penetration
109 1.024 kg perforated plates with adjustable stems - 6 4
110 A tripod for measuring swell - 6 4
111 Dial gauges reading 0.01 mm with a range of 25mm - 8 6
Dial gauge or equivalent with 0.127 mm divisions, range -

112 2 2

Quantity
Item Description
113 Filter paper (CBR) in packs of 100 - 6 4
114 Copper or brass gauze discs of 30 mesh and 170mm dia. - 6 4
Galvanised iron mixing bath , 450 mm x 650 mm x 200 -

115 1 1
mm deep
116 Soaking bath, 300 mm deep - 1 1

case
118 DCP software package - 1 1

119 including a density ring with a 152 mm dia hole for ASTM - 1 1
121 Calibration sieves , 0.425 mm and 0.25 mm - 1 set 1 set
122 Basin 400 mm dia - 1 1
Cylindrical calibration container, internal diameter and -

123 1 1
height 152 mm
124 Glass plate, 180 mm x 180 mm x 7 mm thick - 1 1
125 Hammer, 2 kg - 1 1
126 Chisel, cold steel 25 mm - 1 1
127 Tablespoons - 2 2
128 Containers, tins of 5 litre capacity - 6 4
Particular Specification. Only to be used on approval by

129 - - -
the Engineer
Aggregate Testing
130 Treton Impact Value Device to SANS 3001-AG9 - 1 1
131 Average Least Dimension (ALD) device 1 1

Quantity
Item Description
Concrete Testing

131 (NB One (1)universal compression machine could be - 1 1
Concrete test cube moulds 150mm x 150mm x 150mm, -

132 12 6
Curing tanks, thermostatically controlled, minimum 600 -

133 2 1
134 Slump test device, cone and tamping rod - 1 1
135 Concrete Test Hammer (Schmidt Hammer or similar) - 1 -
136 Straight edge - 2 1
137 Steel ruler - 2 1
138 Sand Equivalent Test Set - 1 1
139 Sand Equivalent Stock Solution (1 kg) - 10 10

(d) List of Laboratory Equipment for Concrete Structures
Quantity
Item Description

General

75.0 mm; 63.0 mm; 50.0 mm; 37.5 mm; 26.5 mm;
1 3 sets 2 set 1 set
19.0 mm; 16.0 mm; 14.0 mm; 12.5 mm; 10.0 mm;
receiver.

2 2.0 mm; 1.70 mm; 1.00 mm; 600 micron; 500 micron; 3 sets 2 set 1 set

4 2 1 1
micron mesh
Electronic weighing scale/balance, 3.5 kg capacity, 0.1 g

6 4 2 1

7 2 1 1

8 2 1 1
calibrated


10 1 - -
single phase

11 - - -

12 - - -
13 Glass plates 0.5 x 0.5 x 0.05 m - - -
Set of Spatulas, 100mm blade, 150mm blade and 200mm

14 6 sets 3 sets 2 sets
blade

Quantity
Item Description

20 1 - -
hopper capacity
26 Thermometer, surface, 64 mm diameter, dial 0 to 160 ºC - - -
28 Thermometer, digital probe, 50 – 300 ºC - - -

Quantity
Item Description
57 Hammer 2.5 kg 1 1 1
61 Slide calipers 1 1 1
65 Pipettes, 5 ml, 10 ml, 20ml, 50 ml and 100 ml 3 sets 2 sets 1 set
71 Trowel 5 no. 3 1

1 set 1 set 1 set

2 1 1

76 10 litre, 15 litre and 30 litre, all with handles except for 3 1 set 1 set 1 set
litre container.

Quantity
Item Description
Aggregate Testing

80 1 1 1

reached in 10 mins suitable for Aggregate Crushing Value
81 1 1 -
rod 16 mm dia, 500 mm long with a hemispherical end.

tested
83 Average Least Dimension (ALD) Device - - -
Concrete Testing


86 50 30 20

87 6 4 2

150mm diameter cores from cementitious and bituminous 1 - -
materials

12 - -
and UCS testing

12 - -
and UCS testing

Quantity
Item Description
92 Concrete Test Hammer (Schmidt Hammer or similar) 1 1 1
Table 1409/4: Laboratory Fittings and Furniture (excluding offices of the laboratory - see Table
1409/1)
Quantity
Item Description
1 Stools, 3-legged, wood or plastic seat, stackable, 800 mm 12 6 3
Shelf space provided against walls shall be of heavy

2 construction and shelving shall be in a suitable timber or 6m 5m 4m
steel material as required
Work bench areas shall be of two types as may be

required (1.5m x 2m):
(1) Wooden construction. The tops shall be hard and
smooth, free from warping or other defects.
3 (2) Concrete tops. The tops shall be at least 75 mm As required
thick concrete slabs with a smooth hard steel trowelled
finish.
All work benches shall be sturdy and the upper surface
shall be 920 mm above floor level
Concrete working floors shall be at least 125 mm thick

and provided with a hard smooth finish. The working
4 Area as required
floors shall be either entirely open or under a lean -to roof
required.
Wash basins shall be as ordered either in stainless steel

or precast ceramic with an area of at least 0.3 sq.m. and
5 3 2 1
minimum depth 0.3 m. They shall be provided with swan
neck type laboratory taps and drain pipe

Quantity
Item Description
Fire extinguishers shall be of the BCF

(Bromochlorodifluoromethane) type manufactured to
BS 1721 and suitable for Types A, B, C and E fires.
The extinguishers shall contain no less than 2.5 kg
6 2 1 1
of extinguishers fluid and shall be fitted to the wall at
a suitable position by means of quick release
brackets. They shall be freshly charged and the
seals shall be unbroken.
File Cabinet, four drawers, lock type, legal size with

7 3 2 1
metal clip hanging files (30 per
8 Electronic Hand Calculator, 6 4 2
Metal Cabinet, 0.40 m X 1.00 m, 1.90 m high,

9 2 1 1
adjustable shelves, lockable
10 Telephone extensions 3 2 1
11 Full international telephone and Internet connection 1 1 1
Desktop computer compatible, having the capacity

12 2 1 1
indicated in the Particular Specifications
Laser printer with carriage for up to A3 paper or as

13 2 1 1
specified in the Particular Specifications

Table 1409/5: Floor area for Engineer’s Office
Area (m²)
Item Description
1 Resident Engineer's Office 20 15 10
2 Assistant Resident Engineer's Office 10 10 -
3 General Office 1 (Pool Office for key staffs) 60 30 20
4 General Office 2 (Pool Office for support staffs) 60 30 -
5 Secretary's Office 10 10 -
6 Conference Room 30 25 -
7 Kitchen Unit 20 15 12
8 toilets + 1 wash basin 10 10 8

Total Area 220 145 50
Table 1409/6: Floor area for Laboratory

2
Minimum Internal Area (m )
Item Description
1 Laboratory testing area (may be partitioned) 100 60 40
2 Oven and soaking room 20 10 10
3 Sample storage 20 10 10
4 Office 40 20 -
5 Store 10 10 10
6 Drying shed 20 10 -
Total Area 210 120 70
Table 1409/7: Floor area for Housing Accommodation to the Engineer

Type A House
2
Minimum Internal Floor Area (m )
Room Type
Living and Dining Area 32 32 -
Kitchen 8 8 -
Bedroom 22 22 -
Bath room 18 18 -
Total area 80 80 -

Type B House
2
Minimum Internal Floor Area (m )
Room Type
Living 12 12 12
Bedroom 12 12 12
Bathroom 6 6 6
Total area 30 30 30
Type C House (Service Quarter) (One or two blocks)
Room Type Option 1 Option 2 Option 3
Number of bedrooms/block 10 6 2
Minimum area of Bedroom (m²) 9 9 9
Bathroom area (common toilet and bath for

6 6 6
two rooms) (m²)
Total area (m²) 120 72 24
Type D House (Mess Hall) (A single Block)

2
Minimum Floor Area (m )
Room Type
Kitchen 24 20 16
Dining room 60 50 40
Lounge 60 50 40
Store 12 10 8
Toilet Ladies and Gents 12 12 12
Total area 168 142 116

Table 1409/8: Equipment for the Engineer’s housing

Type A House
Number
Item Description
Kitchen
Gas or electric Cooking stove with 4 burner grill, oven,

1 1 1 -
and electric hot plate
2 Thermos with glass 1 1 -
3 Kitchen shelf 1 1 -
4 Kitchen table 1 - -
5 Kitchen chairs 4 - -
6 Double sink 1 1 -
7 Large waste bin 1 1 --
8 Fire extinguisher 1 1 -
9 Set of Kitchen Tools and cutlery 1 1 -
10 Set of cooking pots 1 1 -
11 Set of Serving Dishes 1 1 -
12 Set of Plates 1 1
13 Table Cloths 2 2 -
14 Set of cleaning utensils 2 2 -
15 Kettle 1 1 -
16 1.8 X 1.2m work table 1 1 -
17 Set of 6 Tea Cups & Saucers 1 1 -
18 Iron and ironing board 1 1 -
19 Refrigerator 200 litre capacity with freezer box 1 1 -
20 Washing machine (optional) 1 1 -
21 Microwave (optional) 1 1 -
Bedrooms (2)
22 Beds double 1 m + mattress 1 1 -
23 Beds single 1.5 m + mattress 2 2 -
24 Dressing table with mirror and stool 2 2 -
25 Bedside table 3 3 -
26 Bedside chairs 4 4 -
27 Sheets for Double Bed 4 4 -

Number
Item Description
28 Sheets for single Bed 8 8 -
29 Blankets double (Wool) 2 2 -
30 Blankets Single (Wool) 4 4 -
31 Pillows 8 8 -
32 Pillow cases 16 16 -
33 Bed-side carpets 4 2 -
34 Curtains and rails to all windows 1 1 -
Built in or stand-alone wardrobes (app. Size 1980 mm x

35 2 2 -
915 mm x 485 mm)
Living and dining room
36 Dining table (2mx1m app.) 1 1 -
37 coffee table 1 1 -
38 Writing desk with chair 1 1 -
39 Dining chairs 6 6 -
40 Book case (2metre long with 3 shelves) 1 1 -
41 Carpets 1 1 -
1 set per 1 set per

42 Curtains and rails to all windows -
window window
43 3-piece lounge suite 1 1
44 21” colour television 1 1 -
45 Telephone extensions and telephones 1 1 -
46 Satellite receiver and dish with accessories 1 1 -
Bathrooms (2)
47 European toilet 2 2 -
48 Paper holder and toilet brush set 2 2 -
49 Mirror (0.5 sq. m.) 2 2 -
50 Shower unit with basin 2 2 -
51 Large wash hand basin 2 2 -
52 Razor socket 2 2 -
53 Electric boiler 50 litre with waterproof plug/switch 2 2 -
54 Towel rail 2 2 -
55 Bath and hand towel set 8 8 -

Type B House
Number
Item Description
Bedrooms (1)
1 Beds single 1.0 m + mattress 1 1 1
2 Dressing table with mirror and stool 1 1 1
3 Bedside table 1 1 1
4 Bedside chairs 1 1 1
5 Sheets for single Bed 4 4 4
6 Blankets Single (Wool) 2 2 2
7 Bed-side carpets 1 1 1
8 Curtains and rails to all windows 1 1 1
9 Pillows 2 2 2
10 Pillow cases 4 4 4
Living area
11 Coffee table 1 1 1
12 Lounge chairs 2 2 2
13 Book case (2 metre long with 3 shelves) 1 1 1
14 Writing desk with chair 1 1 1
15 Reading Lamp 1 1 1
16 21” colour television with local stations 1 1 1
Bathroom (1)
17 European toilet 1 1 1
18 Paper holder and toilet brush set 1 1 1
19 Bathroom stool 1 1 1
20 Mirror (0.5 sq. m.) 1 1 1
21 Shower unit with basin 1 1 1
22 Large wash hand basin 1 1 1
23 Razor socket 1 1 1
24 Electric boiler 50 litre with waterproof plug/switch 1 1 1
25 Bath and hand towel set 2 2 2

Type C House
No.
Item Description
Each Bedroom in unit
1 Beds single 1.0 m + mattress 1 1 1
2 Bedside table 1 1 1
3 Bedside chairs 1 1 1
4 Sheets for single Bed 4 4 4
5 Blankets Single (Wool) 2 2 2
6 Pillows with pillow cases 2 2 2
7 Curtains and rails to all windows 1 1 1
8 14” colour television with local stations 1 1 1
9 Thermos with glass 1 1 1
10 Set of cleaning utensils 1 1 1
11 Dustbin 1 1 1
Bathroom & Toilet (Common for two rooms)
14 Mirror (0.5 sq. m.) 1 1 1
15 Shower unit with basin 1 1 1
17 Razor socket 1 1 1
18 Electric boiler 50 litre with waterproof plug/switch 1 1 1
19 Towel rail 1 1 1

Type D House (Mess Hall)
Number
Item Description
Kitchen
1 Kitchen shelves 2 1 1
2 Kitchen sink (double) 2 1 1
3 1.8 X 1.2m work table with marble slab 2 1 1
4 Kitchen chair 4 2 2
5 Refrigerator 400 litre capacity with freezer box 2 1 1
6 Freezer 160 litre capacity 1 1 1
Gas or electric Cooking stove with 4 burner grill, oven, 2 1 1

7
and electric hot plate
8 Extension Telephone line 1 1 1
9 Thermos with glass 3 1 1
10 Water filter 1 1 1
11 Dustbins 3 2 2
12 Waste paper basket 3 2 1
13 Fire extinguisher 2 2 2
14 Set of cutlery 3 2 2
15 Set of cooking pots 3 2 1
16 Set of kitchen utensils 3 2 1
17 Set of plates and dishes 3 2 1
18 Table cloth 4 2 2
19 Set of cleaning utensils 4 2 2
20 Rugs 2 1 1
21 Electric kettle 2 1 1
22 Washing machine 1 1 1
23 Set of 6 Tea Cups & Saucers 4 2 1
Lounge/Dining area
24 32” Colour Television 1 1 1
25 Satellite receiver and dish with accessories 1 1 1
26 TV table 1 1 1

1 set (at 1 set (at 1 set (at

least for 20 least for least for 6
27 Dining table and chairs
people at a 10 people people at
time) at a time) a time)
28 Coffee table 4 2 1
29 Dining chairs 20 12 6
30 Lounge chairs 12 6 4
Ladies and Gents Toilets
33 Mirror (0.5 sq. m.) 2 2 2
35 Towel rail 2 2 2
36 Hand towels 4 4 4


Item 14.01 Office Building complete as specified including furniture (Tables 1409/1 and
1409/5)..................................................................................................... Lump Sum (LS)
Payment at the lump sum tendered shall be in full compensation for providing the necessary fittings
and installation thereof and shall include the following specific requirements:
 Preparation of the site;

 Foundations, bases;
 Water, sanitation, power and lighting services ;
 Fences, notice and directional boards ;
 Vehicle access, carports, hard-standing, parking areas and footpaths,
 Telephones, extensions and switchboards (includes the cost of all calls and rental charges);
 Office furniture as in Table 1409/1.
Item 14.02 Laboratory Building complete as specified including furniture (Tables 1409/4 and
1409/6)...................................................................................................... Lump Sum (LS)
Payment at the lumps sum tendered shall be in full compensation for providing the necessary fittings
and installation thereof and shall include the following specific requirements:

 Water, sanitation, power and lighting services;
 Fences, notice and directional boards;
 Vehicle access, carports, hard-standing, parking areas and footpaths,
 Telephones, extensions and switchboards (include the cost of all calls and rental charges);
 Laboratory Fittings and Furniture as Table 1409/4.
Item 14.03 Items measured and paid for by the lump sum
a) Office Equipment and supplies as per Table 1409/2 .................................................. lump sum (LS)
b) Laboratory Equipment and supplies as required and specified in Tables 1409/3 (a), (b), (c) and/or
(d)................................................................................................................................ lump sum (LS)
Payment at the lump sum tendered shall be in full compensation for providing the complete service or
installation and the use thereof including any fixed and usage charges payable to local or other
authorities.

Item 14.04 Services and maintenance

Provision of water, electricity, L.P gas, tanks, sewage and rubbish removal, cleaning services, all as
specified in Clause 1405 and the maintenance of residential accommodation, offices and laboratories
as specified in Sub-clauses 1403(a) and 1404(c); including the construction and maintenance of the
access roads, footpaths, fencing, car parks etc:
a) Fixed Costs ............................................................................................................... Lump Sum (LS)
b) Services and maintenance for residential accommodation, offices and laboratories ..... month (mth)
Payment of the lump sum tendered shall be in full compensation for providing the services specified.
The months during which the Contractor fails to carry out the required maintenance and services
satisfactorily shall not be measured for payment.
Item 14.05 Vehicles for Engineer and his staff

a) Vehicle type A ............................................................................................................... number (No)
b) Vehicle type B ................................................................................................................ number (No)
c) Vehicle type C ................................................................................................................ number (No)
The unit of measurement shall be the number of vehicles which are provided on the Engineer's
instructions and shall include the following specific requirements:
 Equipment;
 Taxing for use on the public highway;
 Comprehensive insurance for any driver;
 Provision of suitable replacement when unavailable;
Item 14.06 Provision of fuel and lubricants and the servicing, maintenance, and repair of
vehicles for the Engineer and his staff
a) Fuel, service and maintain vehicle, Type A ................................................. vehicle-month (veh-mth)
b) Fuel, service and maintain vehicle, Type B ................................................ vehicle-month (veh-mth)
c) Fuel, service and maintain vehicle, Type C ................................................ vehicle-month (veh-mth)
The unit of measurement shall be the number of vehicles multiplied by the calendar month.
d) Fuel, service and maintain vehicle in excess of 3000 km for any vehicle in any one calendar
month, vehicle Type A ................................................................................................. kilometre (km)
e) Fuel, service and maintain vehicle in excess of 3000 km for any vehicle in any one calendar
month, vehicle Type B ................................................................................................. kilometre (km)
f) Fuel, service and maintain vehicle in excess of 3000 km for any vehicle in any one calendar
month, vehicle Type C................................................................................................. kilometre (km)
The measurement for this item shall be based on the cumulative distance travelled by each vehicle.
The item coverage for the tendered rate shall include the following specific requirements:
 Fuel and lubricants;

 Servicing, maintenance and repair;
 Keeping clean inside and out.

Item 14.07 Attendance upon the Engineer and his staff

a) Driver for the Engineer's vehicles ................................................................... man-month (man-mth)
b) Chainman ....................................................................................................... man-month (man-mth)
c) Laboratory Assistants ..................................................................................... man-month (man-mth)
d) Cleaners ........................................................................................................ man-month (man-mth)
e) Watchman/Security ........................................................................................ man-month (man-mth)
The item coverage for the tendered rate shall include the following specific requirements:
 Wages paid including overtime;

 Attendant working outside Contractors normal working hours;
 Costs and expenses incurred consequent upon the employment or hiring of the operative.
Item 14.08 Additional office and laboratory equipment ordered by the Engineer
a) Additional equipment ordered by the Engineer .................................... Provisional Sum (Prov Sum)
b) Laboratory test to be conducted in external laboratories as instructed by the Engineer ................

............................................................................................................Provisional Sum (Prov Sum)
c) Percentage allowed for overhead and profit on items 14.08 (a) and (b) .................. Percentage (%)
Payment for Item 14.08 (a) and (b) shall be the sum of the invoiced amounts for any additional
equipment or testing ordered by the Engineer under this item.
Payment for Item 14.08 (c) shall be the tendered percentage of the amount paid under Item 14.08 (a)
and (b).
Item 14.09 Building, House Type, complete, as specified, including fixtures furniture and
equipment (Tables 1409/7 and 1409/8)
a) Type A housing ............................................................................................................. Number (No)
b) Type B housing ............................................................................................................. Number (No)
c) Type C housing ............................................................................................................. Number (No)
d) Type D housing ............................................................................................................. Number (No)
The measurement for Buildings, House Type shall be the number of units completed in line with the
specifications and drawing and shall include the following specific requirements:

 Water, sanitation, power and lighting services;
 Fences, notice and directional boards;
 Vehicle access, carports, hard-standing, parking areas and footpaths;
 Telephones, extensions and switchboards (include the cost of all calls and rental charges);
 Equipment/furniture as specified in Table 1409/8.

Item 14.10 Items measured by number

a) Air conditioning unit ....................................................................................................... Number (No)
b) Heater ........................................................................................................................... Number (No)
c) Gas burners (including provision of gas installation) ................................................... Number (No)
The unit of measurement shall be the authorised number of units supplied and installed, complete and
in accordance with the Specifications and Drawings and shall include the following specific
requirements:
 Equipment;
 Fittings;
 Brackets;
 Connections, leads, mountings.
Item 14.11 Temporary facilities of the Engineer

a) Office fully fitted, furnished and equipped including all services ............................................. month
b) Laboratory fully fitted, furnished and equipped including all services ..................................... month
c) Housing Accommodation fully fitted, furnished and equipped including all services
(i) Type A houses .............................................................................................................. month
(ii) Type B houses .............................................................................................................. month
(iii) Type C houses.............................................................................................................. month
(iv) Type D houses.............................................................................................................. month
d) Vehicles including all operating costs
(i) Type A ........................................................................................................................... month
(ii) Type B .......................................................................................................................... month
(iii) Type C .......................................................................................................................... month
e) Surveying equipment ............................................................................................................... month
In case the Contractor fails to complete and hand over the complete residential accommodation within
the period stipulated in Clause 1402, a monthly amount (or part thereof) stipulated in Pay Item 14.04
at prevailing rates shall be debited to the Contractor’s account for the period of delay.
The measurement for maintenance of the residential accommodation of the Engineer and his staff
shall be in maintenance months and shall be made on completion of satisfactory maintenance every
month. If at any stage the Contractor fails to carry out the required maintenance satisfactorily, a
monthly amount (or part thereof) stipulated in Pay Item 14.04 at prevailing rates shall be debited to the
Contractor’s account for the period of non-compliance. In addition, the months during which the
Contractor fails to carry out the required maintenance satisfactorily shall not be measured for payment.
The work provided in this item shall be as shown in the Bill of Quantities. The Contract unit rate for
constructing and providing residential accommodation for Engineer/Employer’s supervisory staff shall
include all the expenses for the work described, supply of furniture and equipment, including provision
of uninterrupted supply of water and power.

Item 14.12 Communication Equipment for the Engineer

a) Radio equipment............................................................................................................... Lump Sum
b) SIM card for mobile phone (work-related usage) .......................................................... Number (No)
c) Airtime for work-related SIM card ................................................................................. airtime/month
Payment for item 14.12(a) shall be the lump sum tendered items in full compensation for providing and
maintaining the equipment specified for the number of units required in the Contract.
 The item coverage for the tendered rate for item 14.12(a) shall include the following specific
requirements:
 Provision of all necessary licenses, permissions for wavelengths/channels etc.;
 Equipment and installation;
 Repeaters as necessary;
 Depreciation, maintenance and repairs;
 Replacement equipment due to damage or failure;
 Power supplies including remote locations.
Payment for item 14.12(b) shall be the number of SIM card supplied for work-related usage in areas
that provide mobile phone coverage.
Payment for item 14.12(c) shall be the monthly airtime provided for work-related usage.
Item 14.13 Payment Requirements

Payment of the lump sum tendered items shall be in full compensation for providing the services
specified.
Payment for items 14.01, 14.02, 14.03, 14.04 (a), 14.09, 14.10, 14.11, 14.12 and 14.13 shall be made
as follows:
 80% of the amount will be paid when the item is provided and erected, fitted or installed to the
Engineer’s satisfaction;
 A further 10% will be paid when the value of all permanent work done, excluding escalation,
exceeds one-half of the tendered amount; and
 The remaining 10% will be payable in the certificate which follows the removal of the items
from the site.
Payment at tendered unit rates for the various items of payment scheduled in this Division, shall be in
full compensation for providing, procuring erecting, installing and/or fitting the item or service as may
be required or specified, for the use of the item or service including replacements when defective and
all transport, handling and other costs.
For time related cost items, the rate shall continue to be applicable during any extended period of the
construction work, unless other rates are agreed by the contracting parties.
Payment under Item 14.05 shall be made in full in the payment certificate following the date of
handover of the vehicle to the Engineer.

Division 1500: Traffic Management
1501 Scope
This Division covers the construction and maintenance of temporary traffic diversions, barricades,
signs, and the provision and operation of traffic lights and everything necessary for the safe and easy
passage of all public and construction traffic during the performance of the Contract including the
reinstatement of traffic diversions.
This Division also covers the maintenance of the existing project roads for public traffic where
possession of the Site is given to the Contractor in accordance with the Conditions of Contract; and
the construction and/or maintenance of hauling and access roads in the project.
a) General
It is the intention of the Contract that traffic should be able to conveniently pass along the road to be
upgraded at all times during construction and all weather conditions. The Contractor shall be
responsible for providing a good quality access to the public through or around the Works. The
Contractor shall be at liberty to pass traffic through the Works.
The Contractor shall be aware that maintenance of existing roads, as well as diversion roads, and
protection of traffic through the Works during construction, is considered of equal importance to the
actual construction. The Contractor shall at all times conduct his operations in a manner to ensure the
convenience and safety of motorists, pedestrians and adjoining property owners as well as the safety
of his own employees and those of the Engineer.
For the purpose of this clause, the road reserve means the Site as defined in Division 1100, clause
1102.
No vehicle shall be held up by the Contractor’s work for more than ten (10) minutes at any one
working area, except at river crossings where the construction of a service road is practically
impossible.
The existing road reserve shall be handed over to the Contractor in sections (separate lengths of road)
for maintenance purposes in accordance with the requirements of the work’s programme and as
agreed, unless otherwise specified by the Engineer. Road sections for which the Contractor has
occupation shall be maintained to the satisfaction of the Engineer.
The Contractor shall:
 Provide road safety education and workshops to the staff, operators, drivers and employees of
the Contractor, Sub-Contractors, Engineer and suppliers. The local police and the Regional
Bureau of Labour and Social Affairs should also be invited to participate;
 Make every effort to minimise road safety hazards and inconveniences to other road users
resulting from the passage of his or his sub-contractor’s haulage vehicles and construction
equipment;
 Impose and enforce compliance with speed limits, especially at active construction sites and
in rural towns;
 Ensure that all diversions and detours used for the works shall be watered at least three (3)
times a day during the dry season to suppress dust for health and safety reasons.

The Contractor shall prepare and submit a Traffic Management Plan (TMP) for the entire, or agreed
sections, of the road. The TMP shall be prepared based on the Client’s Road Safety Audit Manual, or
any other document approved by the Engineer, and include all the requirements stated in Division
1500 and sub-clauses 1602 (b) and 1611 (c) of Division 1600. The Plan shall be submitted to the
Engineer for approval and final acceptance by the Employer.
The Plan shall consider the provision of the following, but not limited to:
 Diversions with suitable and reflecting road signs;

 Barricades, delineators and flagmen to guide the traffic:
 For regulation of traffic, the flagmen shall be equipped with red and green flags;
 At night, the passage shall be delineated by reflectors or other similar suitable materials;
 Deep cuts of the ground or road surface more than 150 mm at any location accessible by road
users shall be protected to avoid any potential accidents;
 Alternative pedestrian routes where these are interrupted;
 Clear, suitably labelled and meaningful traffic signs and speed limits, especially at designated
road crossings for people and animals;
 One-way traffic operation where the traffic is to be passed over part of the carriageway
inadequate for two lane traffic. This should only be considered where the topographical and
environment restrictions do not allow widening of the works road sections or provision of any
diversions. This should be done with the help of temporary traffic signals or flagmen;
 Traffic awareness workshops, especially at schools, churches and other community meeting
places at agreed times during the construction works, but at least at the start and end of each
school semester;
 Accident protection structures (eg concrete slabs) painted with reflective paint and placed at
schools, churches and other community gathering areas which are close to the road reserve.
The key summary of the TMP shall be distributed to the entire staff, operators, drivers and employees
of the Contractor, Sub-Contractor, Engineer and suppliers. The Contractor shall also conduct a
“Safety Awareness and Enhancement meeting” every week at a pre-fixed date and time for attendance
by the entire staff, operators, drivers and employees of the Contractor, Sub-Contractor, Engineer and
suppliers.
The Contractor shall not commence any work prior to the approval of the detailed TMP by the
Engineer and before completing a series of initial external and internal “Safety Workshops” as
approved by the Engineer.
At the end of the project, the Contractor shall prepare a detailed completion report on the traffic
management implementation activities. The report shall contain:
 The detailed activities carried out during the project life;

 Problems encountered;
 A comparative analysis of the various actions carried out by the Contractor; and
 Lessons learned for inclusion in future projects.
The Contractor shall plan for maintaining the flow of through traffic at all times. In exceptional
circumstances road closures of up to one (1) hour duration may be permitted by the Engineer. The
Contractor shall give reasonable notice of any proposed road closures and shall comply with all
regulations relating to the temporary closure of the road.
On completion of a day's work the Contractor shall leave the Works in a condition that allows the safe
passage of through traffic.
Should the road width be restricted or should there be any form of obstruction or danger to traffic, the
Contractor shall supply adequate flagmen, signs, barriers, lights, communications and staff to ensure
that the traffic is safely conducted though the Works.
Non-compliance by the Contractor to ensure that traffic is accommodated safely may result in
suspension of the Works by the Engineer in accordance with the Conditions of Contract until the
Engineer is satisfied that all necessary safety measures are in place.
b) Default by the Contractor

If, in the opinion of the Engineer, any Work within this division is urgently necessary for the safety of
the traffic; and the Contractor is unable or unwilling to do such work immediately; the Employer shall
be entitled to employ and pay other persons to carry out such work as the Engineer may consider
necessary. All costs consequent thereon or incidental thereto shall, after due consultation with the
Employer and the Contractor, be determined by the Engineer and shall be recoverable from the
Contractor by the Employer. This may be deducted by the Employer from any monies due or to
become due to the Contractor; and the Engineer shall notify the Contractor accordingly, with a copy to
the Employer.
c) Minimum Vertical Clearance

The minimum vertical clearance over any portion of a bypass shall be 5.3m.
If the minimum clearance available is less than 5.3m, the minimum clearance shall be indicated on
approved signs at approved locations on and in advance of the obstruction.
d) Property and Survey Monuments

Where possible, Traffic Diversions shall be constructed so as not to damage or displace property or
trigonometrical survey monuments. In exceptional cases where this is not possible the Contractor shall
notify the Engineer in good time so that he may arrange to have these suitably referenced before they
are displaced. The Contractor shall be responsible for relocation or suitably referencing and later
reinstatement of such monuments or beacons, at his own cost.
e) Access to Properties
The Contractor shall provide and allow access to persons whose properties fall within or adjoin the
area over which he is working and in this respect the Contractor's attention is drawn to the Conditions
of Contract. No separate payment shall be made for the provisions and maintenance of such accesses
and facilities, except where they extend beyond the road reserve.
f) Public services
Public services affected by temporary diversions shall be treated in a similar manner as services
affected by the permanent Works and payment shall be made in accordance with the provisions of
Division 1200 of these Specifications.
g) Temporary works
The Traffic Diversions provided by the Contractor shall include the construction of temporary fences,
drainage works, and other incidentals considered necessary by the Engineer.
Prior to commencement of the temporary Works, the Contractor shall submit drawing for the approval
of the Engineer. In the case of temporary traffic diversions, these shall include but not be limited to:
 Pavement type and width;

 Pedestrian facilities, if any and access to adjacent properties;

 Length of diversion and the expected duration of its use;
 Access and egress arrangements;
 Temporary drainage arrangements;
 Temporary traffic control, signage and markings.
h) Approval of Temporary Traffic Diversions

The need for, and details concerning, all temporary traffic diversions shall be approved by the
Engineer before the start of construction and the Contractor shall satisfy himself before tendering that
he can arrange for temporary traffic diversions as may be necessary for the safe and convenient
passage of traffic.
The Contractor shall before the start of construction submit a detailed plan concerning all temporary
traffic diversions for approval of the Engineer.
1503 Traffic Barriers, Signing and Lighting
a) Traffic Barriers
The Contractor shall provide, erect and maintain barriers and barricades to the satisfaction of the
Engineer.
Traffic control facilities such as STOP/GO signs and radios shall be available at both ends of those
sections of the Works where the road is barricaded and only one-way traffic is accommodated. A set
of two-way radios in good working order shall be available in such instances.
When movable temporary signs are used, provision shall be made for sandbags on the sign bases to
prevent the signs from being overturned by wind or eddies from passing vehicles.
The Contractor shall erect movable shelters to protect the personnel manning the sections and provide
safety jackets with retro reflective material.
Accommodation of traffic over existing bridge structures shall be effected by means of traffic lights on
a one-way system traffic flow. (See sub-clause (c)).
b) Traffic Signing
The Contractor shall provide traffic signs and warning boards (including warning lights where
necessary) and a sufficient number of flagmen to ensure that all necessary precautions for the
protection of the Works and for the safety of the travelling public are met.
c) Traffic Lights
The Contractor shall provide traffic control by means of three-phase traffic lights at locations where
there is inadequate width for two-way traffic or where construction plant disrupts the flow of through
traffic.
Traffic lights used in these circumstances shall be permanently manned.
1504 Construction of Temporary Traffic Diversions

Where described in the Contract, the Contractor shall provide temporary traffic diversions for the
public traffic around the Works.
The temporary traffic diversions provided by the Contractor shall include the construction of all
necessary temporary fences, drainage works and other incidentals. The Contractor shall also ensure

dust suppression, pedestrian access and access to properties along the whole length of each
diversion for the duration of its use and shall remove the diversion on completion of the Works.
The maximum length and minimum width shall comply with the following:
a) Maximum Length
Unless otherwise permitted by the Engineer the maximum length of a temporary traffic diversion shall
be 5 kilometres in rural areas and 1 kilometre in urban areas or as instructed by the Engineer.
There shall be 10 kilometres of maintained and trafficable existing road between two consecutive
diversions with the exception of construction of the Works in half width.
b) Minimum Width
Temporary traffic diversions shall be a minimum of 3.5 metres and 7.5 metres width for single and two-
way traffic respectively or as instructed by the Engineer.
1505 Accommodation of Traffic Where the Road Is Constructed In Half Widths

One-way traffic operations, where traffic is to be passed over part of the carriageway inadequate for
two lane traffic, may be established only in such cases where the topographical and environmental
restrictions do not allow widening of the Work’s road sections or provision of any diversions. The
lengths of the half-width construction shall be kept to a minimum, with provision for traffic travelling in
opposite directions to pass at frequent intervals.
The Contractor shall so arrange his work that the traffic will at all times have free one-way access to at
least half the width of the roadway during the construction period. He shall maintain that half of the
road, which is being used for traffic at that time, to the satisfaction of the Engineer.
The maximum length of a single working lane shall be 1 kilometre, subject to the Engineer’s approval
based on the specific site conditions. Adjacent sections of single lane working must be separated by
not less than 1 kilometre of full width carriageway to permit two-way traffic to stabilise. The minimum
single lane carriageway width shall be 3.5 metres.
One-way traffic operations shall not be allowed after dusk and before dawn (during night-time hours).
Should the road not be in a safe trafficable condition for two-way traffic over the whole width at the end
of each day's work, the Contractor shall supply adequate flagmen, signs barriers, lights and necessary
staff, at his own cost, to ensure a reasonable free flow of traffic alternately in each direction throughout
the whole period that the roadway is open to one-way traffic.
Temporary traffic signals or flagmen shall be kept in position at all times, on opposite sides of the one-
way traffic operation. The flagmen shall be equipped with red and green flags. The Contractor shall
provide alternative pedestrian routes where these are interrupted and shall use clear, properly labelled
and meaningful traffic signs and speed limits, especially at road crossings for people and animals.
1506 Temporary Drainage Works

The Contractor shall construct the necessary temporary drainage works such as side drains, catch
water drains, mitre drains and culverts, to deal adequately with any surface run-off.
Temporary culverts shall be installed on existing drainage channels wherever required by the Engineer
and of sizes and types ordered by the Engineer. Any suitable metal or precast concrete culverts
salvaged from an existing road or abandoned bypass may be re-used if in a good condition and

1507 Earthworks for Traffic Diversions

The Contractor shall shape and grade the Traffic Diversions making full use of all material that can be
obtained from alongside the Traffic Diversions, from side cuts or from the immediate vicinity. If
sufficient material cannot be obtained in this manner, the Contractor shall import material from other
sources. Where necessary, cuts shall be made to obtain a satisfactory vertical alignment.
The Contractor shall also perform the necessary clearing and grubbing including the removal of all
trees and stumps. Where the existing ground is not sufficiently dense in its natural condition, it shall be
compacted as specified in Series 4000 for earthworks in these Specifications prior to the construction
of the earthworks for the diversion.
All fill material shall be spread and compacted in accordance with Series 4000.
1508 Gravelling of Traffic Diversions or of Existing Roads used as Traffic

Diversions
When the earthworks for Traffic Diversions as described in Clause 1507 have been completed, those
sections of the Traffic Diversions, and of existing gravel roads used as Traffic Diversions as indicated
by the Engineer, shall be provided with a wearing course of suitable granular material approved by the
Engineer.
The Contractor shall provide, spread, water, mix and compact such material to a density where it can
carry traffic without undue wear and tear. The granular material shall be spread and compacted in
accordance with Series 5000.
In case of disagreement between the Engineer and the Contractor as to the adequacy of the
compaction, a dry density equal to 95% of AASHTO T180 density shall be taken as the required
minimum density.
1509 Selected Gravel Layers, Crushed Stone or Asphalt Base, Stabilisation,

and Road Markings required for Bitumen-Surfaced Temporary Diversions
Where specified in the Particular Specifications or required by the Engineer, gravel layers of selected
subgrade or sub-base quality, crushed stone base, asphalt base or stabilised gravel layers shall be
constructed and road markings (on bitumen surfaces) shall be done by the Contractor, all in
accordance with the requirements of the relevant clauses of these Specifications and the Engineer's
instructions.
1510 Existing Roads used as Temporary Diversions

Where existing roads are to be used as temporary diversions, the Contractor shall, after consultation
with the Owner or Authority having control of such road, carry out any repairs, alterations or additions
to such roads as may be required to bring them to a condition suitable for traffic. This work will be paid
for as stipulated hereinafter.
1511 Bitumen Surfaced Temporary Diversions

Where required in the Particular Specifications or by the Engineer, temporary diversions shall be
provided with bituminous surfacing in accordance with the requirements of Series 6000 or of the
Particular Specifications or as instructed by the Engineer.

1512 Maintenance of Gravel Traffic Diversions

All gravel Traffic Diversions shall be maintained by the Contractor in a safe trafficable condition.
Whenever required by the Engineer, the traffic diversion shall be bladed and rolled by means of self-
propelled graders and rollers to provide a smooth riding surface free of corrugations. All potholes shall
be promptly repaired.
The Contractor shall water the Traffic Diversions to keep down dust or in order to facilitate the proper
blading of the surface. All drainage works shall be maintained in good working order.
1513 Maintenance of Existing Roads

All existing roads within the Site handed over to the Contractor, shall be maintained by the Contractor
in a safe trafficable condition. Wherever required by the Engineer, gravel roads shall be bladed and
rolled by means of self-propelled graders and rollers to provide a smooth riding surface free of
corrugations. All potholes shall be promptly repaired.
The Contractor shall water the gravel roads to keep down dust or in order to facilitate the proper
blading of the surface. All drainage works shall be maintained in good working order.
1514 The Contractor's use of Traffic Diversions

When the Contractor constructs Traffic Diversions, haul or construction roads through the Contractor’s
own initiative for accommodating construction traffic, the Contractor shall construct and maintain them
at the Contractor’s own cost and only in accordance with details previously agreed upon in writing with
the Engineer. Such roads shall be removed and the surface properly reinstated when no longer
required, also at the Contractor's own cost.
The Contractor shall have the right to use public roads including Traffic Diversions open to public
traffic. Where the Contractor’s own traffic causes excessive damage or wear to such roads; or
constitutes a hazardous condition to public traffic; the Engineer shall have the right to regulate the
Contractor’s traffic over such Traffic Diversions. In such circumstances the Contractor shall provide, at
the Contractor’s own cost, such maintenance, including wearing course gravel and watering, as in the
Engineer's opinion is necessary in addition to what would be required to properly maintain the Traffic
Diversions when not used by the Contractor's construction traffic. Where regulation of the Contractor's
traffic does not alleviate the traffic hazard satisfactorily; or the maintenance of the Traffic Diversions
cannot be or is not properly executed; the Contractor shall, where conditions permit, divert his traffic
over construction roads provided and maintained at the Contractor’s own cost.
1515 Removal of Traffic Diversions

On completion of the permanent Works, unless agreed otherwise in advance with the Local
Administrations and Communities and covered by a confirmation letter, diversions shall be reinstated
to their original state by the Contractor.
The following steps shall be taken in the reinstatement of diversion roads constructed in farmlands and
grazing lands away from existing roads:
 Preservation of the topsoil in stockpiles during the construction of the diversion for future
replacement;
 Removal of the selected materials used (disposal shall be as directed by the Engineer);
 Loosening of the compacted soils using a ripper;
 Spreading of the preserved topsoil to facilitate re-vegetation.

Item 15.01 Temporary Diversions

a) Construction of Diversions ........................................................................................... kilometre (km)
b) Maintenance of Diversion ............................................................................................ kilometre (km)
c) Reinstatement of Diversion ......................................................................................... kilometre (km)
d) Traffic Management – full width ................................................................................... kilometre (km)
e) Traffic Management – half-width ................................................................................. kilometre (km)
The unit of measurement for construction, maintenance and reinstatement shall be the kilometre,
measured along the centrelines of temporary diversions; existing roads used as temporary diversions;
and roads constructed in half-widths. It shall not include sections along which the traffic is diverted
onto existing roads where the Contractor is not responsible for the maintenance of such existing
roads.
The unit of measurement for traffic management shall be the kilometre measured as the length along
the project road.
The tendered rate for construction shall include full compensation for:
 Clearing and grubbing, all earthworks, grading, shaping, gravelling, watering, mixing and
compacting of temporary diversions, including roads constructed in half-widths and existing
roads used as temporary diversions during construction and maintenance periods;
 Excavating, procuring, furnishing and placing of all classes of material including loading,
transporting and offloading;
 Loading, transporting, offloading, shaping and levelling of spoil material;
 Procuring and furnishing new culverts including all excavations, bedding, laying and
backfilling;
 Arranging for the moving of services and solving the associated traffic problems;
 Providing temporary access to private properties;
The tendered rate for maintenance shall include full compensation for:
 All maintenance activities for the duration of the temporary diversion, to the satisfaction of the
Engineer.
 Maintenance of existing roads for which the Contractor has responsibility as part of the
Contract agreement;
 Maintenance of temporary drainage;
The tendered rate for reinstatement shall include full compensation for:
 Removing traffic diversions, reinstatement to its natural condition and all necessary traffic
management
 Grubbing, all earthworks, grading, shaping, gravelling, watering, mixing and compacting
The tendered rate for traffic management shall differentiate between half-width and full-width and shall
include full compensation for:
 Providing barriers, signage, flagmen and communication equipment required for regulating the
traffic for full- and half-width construction as approved by the Engineer;

 Complying with the legal requirements of all authorities concerned;

 All necessary traffic management throughout the period of the temporary diversion.
Payment shall be made in two equal instalments:
 The first instalment shall be made when suitable temporary diversions have been constructed
and approved for use; or when traffic is taken over half-width construction;
 The second instalment shall become due when traffic can be accommodated on the new road,
all temporary deviations have been removed and reinstated, and all general obligations of the
Contractor have been complied with to the satisfaction of the Engineer.

Division 1600: Social, Health, Safety and Environmental Protection

and Mitigation Measures
1601 Scope
This Division covers all work necessary for the protection, health and safety of project staff, the
affected communities and the environment, including the mitigation measures to be taken. It also
covers specific requirements related to community involvement and interactions during the project.
The Contractor is also referred to Division 1200 and Series 9000 of these Specifications.
The environmental protection and mitigation measures shall require the Contractor to fulfil any regional
and national statutory requirements and liaison with local, regional and national authorities with
respect to environmental issues.
Environmental aspects of the Works shall include, but not limited to; all camp sites, quarries, borrow
pits, water sources, temporary diversions, existing roads used as diversions and storage sites in
addition to the main project Work Site.

Prior to commencement of any civil works on the project site, the Contractor shall prepare and submit
the following environmental and social safeguard plans for review and approval of the Engineer and
final acceptance by the Employer. Each plan shall be separate and independent and at a minimum
shall meet the requirements or recommendations shown in these Technical Specifications and the
relevant guidelines and laws:
 Site Environmental and Social Management Plan (SESMP) as specified in Clauses 1603 to
1612;
 Traffic Management Plan as specified in Division 1500;
 Health and Safety Plan as specified in Clause 1613;
 Plan for the implementation of an HIV/AIDS alleviation programme in line with Clause 1614;
 Plan for explosives handling and blasting operation in line with Clause 1210.
The Contractor shall prepare and submit these safeguard plans at least thirty (30) days prior to the
commencement of any civil works for section(s) or the entire road project, for approval by the Engineer
and final acceptance by the Employer. The plans shall be developed on the basis of the requirements
or recommendations specified in these Technical Specifications; the Environmental and Social
Management Manual (ESMM) of ERA; the project Environmental and Social Impact Assessment
(ESIA) and Resettlement Action Plan (RAP) documents; the overall Environmental Policy of Ethiopia;
and the relevant environmental laws, regulations and guidelines, including the World Bank Safeguard
Policies.
1603 Site Environmental and Social Management Plan (SESMP)

At least thirty (30) days prior to commencement of the Works, the Contractor shall prepare a
comprehensive SESMP for section(s) or the entire road project with a timeframe for actions to ensure
proper implementation of the project as per the ESMM, the ESIA and RAP, National Government
Environmental Policies and Guidelines. The SESMP shall be prepared and submitted by the
Contractor for approval by the Engineer and the Employer prior to commencement of the Works. The
SESMP shall be in accordance with the relevant sections of the ESIA, RAP and World Bank
Safeguard Policies and shall include the requirements of the relevant Divisions and Clauses of this
Specification.
The prevailing versions, with amendments, of the following documents are among the environmental
policies, laws and regulations that shall be binding on the Contractor:
 The Constitution (FDRE, 1995), contains a number of articles, which are relevant to
environmental matters in connection with development projects, as well as to the environment
in general, and forms the fundamental basis for the development of specific environmental
legislative instruments. Article 92 of Chapter 10 provides environmental objectives stating that
development projects shall not damage or destroy the environment; and Government and
citizens shall have the duty to protect the environment.
 Proclamation on Forest Development, Conservation and Utilization, No. 542/2007: This most
recent legislation on forests was issued in September 2007 to provide for the development,
conservation and sustainable utilisation of forests. It provides direction for the development
and utilisation of private and state forests as well as prevention of forest fire, production and
movement of forest products.
 Proclamation on Environmental Pollution Control, No. 300/2002, is mainly based on the right
of each citizen to have a healthy environment, as well as on the obligation to protect the
environment of the Country. The Proclamation states that the “polluter pays” principle shall be
applied to all persons.
 Proclamation on Research and Conservation of Cultural Heritage, No. 209/2000 provides a
legal framework for Research and Conservation of Cultural Heritage. Article 41 is on
Fortuitous Discovery of Cultural Heritage and Sub-Article (1) states that, any person who
discovers any Cultural Heritage in the course of an excavation connected to mining
explorations, building works, road construction or other similar activities, or in the course of
any other fortuitous event, shall forthwith report same to the concerned Authority, and shall
protect and keep same intact until the concerned Authority takes delivery thereof.
 Proclamation on Development, Conservation and Utilization of Wildlife, No. 541/2007, is to
conserve, manage, develop and properly utilise the wildlife resources of Ethiopia. Article 8 (1),
states that no person, other than the Ministry of Agriculture and Rural Development, or the
concerned regional organisation in the discharge of their duties, may hunt any game animal
unless he is in possession of a hunting permit.
 The contractor shall comply with the country’s Proclamation on Occupation Safety and Health,
No.377/2003 that states legal requirements to be taken at workplaces to protect the safety and
health of workers.
The SESMP shall include the management of environmental safeguard requirements and operational
health and safety requirements; and shall be submitted to the Engineer and the Employer at least
thirty (30) days prior to the commencement of any civil works. The SESMP shall be developed either
for a specific road section or entire section of road and should also be updated twice yearly or as
instructed by the Engineer during the project construction period and defects liability period.
The SESMP shall include provisions for monitoring safeguards on the project, including an
Environmental Audit Plan (EAP), which is a procedure for managing non-compliances. The Contractor
shall monitor the implementation of these plans in collaboration with the Engineer and the
Environmental Supervisor of the Employer.
The Contractor shall appoint a full-time, qualified Environmental Officer having at least a Bachelor’s
Degree in Environmental Sciences or related fields and three (3) years of experience in Environmental
Impact Assessment or Environmental Monitoring Activities. The Environmental Officer shall monitor
and report on the project with respect to environmental aspects of the contract and the approved
SESMP.
The Contractor shall submit monthly to the Engineer, with copies to the Employer and the
Environmental Authority, a compliance report describing the actions that have been taken
corresponding to each of the requirements to be fulfilled by the Contractor as specified in these
Specifications. The report shall be prepared in a format approved by the Engineer.
The Engineer should satisfy himself, prior to approval of the SESMP that all reasonable precautions
have been or will be taken into account to minimise adverse environmental impacts. The Contractor
shall take responsibility to create awareness among the Workforce and the general public about the
protection of the natural environment, maintaining of vegetation and wild life, keeping water sources
clean, etc.
In the case of interventions for camps, quarry sites, borrow pits, crusher sites, etc., the sites shall be
photographed prior to exploitation so that monitoring of reinstatements will be effective.
The SESMP should contain, but not limited to, the following issues:
 A clear description of the baseline environment that is the environmental and social condition
prior to commencement of the project;
 A detailed description of the adverse environmental and social impacts expected to be caused
by the project activities;
 The recommended avoidance, mitigation or offset measures for each potential adverse
impact;
 Specific timing and responsibilities for the implementation of the recommended mitigation
measures of the actions to be taken;
 A programme with responsibilities for supervision or monitoring of the agreed targets;
 Reporting, audit and review procedures;
 A site plan showing the location and proposed extent of the borrow pits, quarry sites, access
roads and any other facilities which may be utilised;
 Details of all landholdings, vegetation and land use;
 Measures which should be taken to reinstate all sites and make the borrow pits and quarry
sites safe on completion of exploitation; and to rehabilitate any agricultural land which has
been affected by the construction and operation of any access and diversion roads;
 Measures which will be taken to minimise the adverse impacts of the road construction as
summarised in Clause 1614 and as indicated in other sections of these Specifications.
1604 Landscape Preservation
(a) General
The Contractor shall exercise due care to preserve the natural landscape and shall conduct his
construction operations so as to prevent any unnecessary destruction, scarring, or defacing of the
natural surroundings in the vicinity of the Work. Except where clearing is required for permanent
Works, approved construction roads and earthworks operations; all trees, native shrubbery, and
vegetation shall be preserved and shall be protected from damage by the Contractor’s construction
operations and equipment. The edges of clearings through trees, shrubbery, and vegetation shall be
irregularly shaped to soften the undesirable visual impact of straight lines. Movement of labour and
equipment within the RoW and over routes provided for access to the Work shall be performed in a
manner to prevent damage to grazing land, crops, and/or property.
With the exception of the provisions in Series 4000, special reseeding or replanting will not be required
under this Specification. However, on completion of the Works, all work areas not seeded shall be
scarified and left in a condition which will facilitate natural re-vegetation; provide for suitable drainage;,
and prevent erosion. All unnecessary destruction, scarring, damage, or defacing of the landscape
resulting from the Contractor’s activities shall be reinstated, replanted, reseeded or otherwise
corrected as directed by the Engineer at the Contractor’s own cost.
In the Contractor’s reinstatement works of all construction sites, the following steps shall be taken:
 If farmland or grazing lands which are away from the existing roads are used for construction
purposes, then the following steps shall be taken toward its reinstatement:
 Preservation of the top soil during the construction;
 Removing the selected materials used (disposal shall be as per the direction of the Engineer);
 Loosening the compacted soil using a ripper;
 Spreading the preserved topsoil so that it allows re-vegetation.
The Contractor shall submit a detailed environmental completion report incorporating all the activities
carried out and submit to the Engineer and the Employer for approval.
(b) Temporary Traffic Diversions and Haul Roads

The location and alignment of temporary traffic diversions and haul roads shall be subject to the
approval of the Engineer. On completion of permanent works, unless agreed otherwise in advance
with the local administrations and communities, diversions shall be reinstated to their original state.
In cases where haul roads pass through towns or major settlements the Contractor shall prepare and
submit construction traffic management plans to the Engineer for approval. The plan shall set out
clearly the steps which will be taken to minimise the impacts of haulage traffic, including but not limited
to, the regular watering of unsurfaced sections to suppress dust and the control of speed limits.
(c) Contractor’s Facilities

Workshops, offices, storage and plant areas shall be located and arranged in a manner that will
preserve trees and vegetation to the maximum extent that is practicable. On abandonment, all
temporary buildings, including concrete footings and slabs, and all construction materials and debris
shall be removed from the Site and disposed of to the satisfaction of the Engineer. The area shall be
re-graded as required so that all surface drainage blends naturally into the existing terrain, and left in a
condition that will facilitate natural re-vegetation, provide for suitable drainage, and prevent erosion.
(d) Blasting Precautions

In addition to the requirements of local regulations, the Contractor shall adopt precautions as required
in Clause 1210 when using explosives, which shall prevent scattering of rocks, stumps, or other debris
outside the work area, and prevent damage to surrounding trees, shrubbery and vegetation.
(e) Quarries, Borrow Pits, Plant and Storage Areas

Site selection and development of quarry and borrow sites shall be in an environmentally and socially
sensitive manner. Therefore, the Contractor shall prepare a detailed SESMP for each proposed site for
approval by the Engineer, the Employer and the concerned Wereda Administration or Wereda Land &
Environmental Protection Office (WLEPO), prior to commencement of any site development; and
execute all works at the site in accordance with the plan. The SESMP should address appropriate
methods or procedures required to minimise potential environmental and/or social impacts to
acceptable levels. The SESMP shall include the following, but not limited to:

 A site plan showing the location and proposed extent of the proposed site (quarry, borrow,
camp, materials processing plant or storage site), access road and any other facilities, which
may be installed;
 Existing land use and land cover and details of landholdings and land acquisition plan;
 Avoidance of proposing quarries, borrow sites, access roads and/or Contractor’s site facilities
close to environmentally or socially sensitive areas including the following:
o Settlement areas, social services such as schools and health facilities as well as
religious institutions (churches & mosques) within 1.5 km of the site facilities;
o Prime agricultural lands;
o Culturally significant sites;
o Areas vulnerable to slope instability;
o Areas with significant aesthetic value;
o Water bodies such as springs, streams, rivers or lakes; except for river sand and
gravel sediments not directly affecting river flows;
o Protected forest areas;
o Areas containing protected indigenous tree species;
o Other sensitive areas that may be specified by the Engineer or the concerned
WLEPO.
 Measures to be taken to minimise disruption of drainage systems and erosion caused by
access roads;
 Pictorial evidence of the selected sites before commencement of the site development along
with a list of all tree species found within the selected site(s) and the exact number of trees.
The Contractor shall undertake these actions in the presence of the Engineer, in collaboration
with a Forester or Environmentalist from the Wereda Forestry Department or WLEPO;
 A site restoration plan for the selected quarries, borrow pits, camps, plants and storage sites
where the major works of a section of the road has been substantially completed. No site shall
be left open, unless otherwise approved by the Engineer and requested by the local
administrations and communities that the sites remain open permanently for their own
purposes. For sites that are left open, the Contractor shall provide, with an approval from the
Engineer, the necessary protective facilities such as fences, drainage facilities, slope
stabilisation measures, etc., to ensure the safety of local people, especially children and
animals. The reinstatement works shall include the following activities:
o Preservation of the topsoil during establishment of the sites;
o Removal of the selected/foreign materials. Materials suitable for further use, shall be
collected by the Contractor and dumped at quarry sites or other sites proposed for
reinstatement/landscaping;
o Loosening compacted soils using a ripper;
o Landscaping, levelling, shaping and compacting the sites in order to provide suitable
drainage and avoid ponding and stagnation of surface water;
o Spreading of the preserved topsoil uniformly over the surface to at least 5cm
thickness to promote growth of vegetation, enhance agricultural production, and/or
improve animal grazing;
o The erection of barriers around areas which cannot be reinstated to the surrounding
topography and are deep enough to hold water, to prevent accidents to people and
animals after completion of the Works;

o Planting of appropriate indigenous tree species, shrubs and/or grasses as part of

reinstating the sites to recover the original vegetation and to improve the aesthetic
value of the sites. Tree planting and grassing shall be implemented according to the
specifications shown in Division 9600.
o The reinstated quarry and borrow sites, access roads, camps, materials processing
plant sites and other construction sites shall be subject to approval by the Engineer
and the WLEPO before handing over of the sites.
(f) Spoil Disposal

The Contractor shall be aware of the amount of spoil materials generated from road cuts and other
excavations, and prepare detailed plans for the disposal of the materials in an environmentally and
socially friendly way. The spoil disposal plan shall be in compliance with the environmental objectives
of the Constitution of FDRE (Procl. No. 1/1995, or superseding versions), Ethiopian Environmental
Policy (1997, or superseding versions), laws and regulations specified in the project ESIA, ESMM of
ERA, and the recommendations of the project ESIA and RAP as well as the World Bank Safeguards
Policies. To this effect, the Contractor shall adopt appropriate methods or procedures for the selection
of suitable spoil disposal sites and disposal activities, including the following, but not limited to:
 Identification and assessment of proposed spoil disposal sites for approval by the Engineer
and final acceptance by the Employer and the concerned Wereda administration or WLEPO
prior to commencement of any civil works that will generate spoil materials.
 Sites shall not be selected at or near environmentally or socially sensitive areas including the
following:
o Farmlands used by the local people for crop production;
o Areas vulnerable to erosion or slope instability and steep slope areas;
o Areas with significant aesthetic value;
o Areas close to, or in water bodies (eg springs, streams, rivers or lakes) or on river
banks;
o Protected forest areas;
o Areas containing protected indigenous tree species;
o Areas in close proximity to settlement areas and social services such as schools,
health facilities, water supply systems or lines, power and telecommunication lines;
o Areas of cultural or religious values such as religious institutions (eg mosques and
churches), and cemeteries or burial places;
o Other sensitive areas that may be specified by the Engineer and the concerned
WLEPO.
 Side-tipping of spoil materials down slopes or at or near environmentally or socially sensitive
areas shall be strictly prohibited and could lead to suspension of the construction works until
rectified;
 Excess excavation or spoil materials, as far as possible, shall be used for backfilling of borrow
and quarry sites in order to reinstate the sites as specified in sub-clause 1602;
 Cut or excavation materials that meet the quality standards shall be used, as far as possible,
for embankment fill and other fill requirements;
 Excess spoil materials shall only be disposed of at suitable selected disposal sites that have
been approved by the Engineer and accepted by the concerned Wereda administration or
WLEPO prior to commencement of disposal activities;
 Preparation of specific Site Restoration Plans for each proposed and approved spoil disposal
site. The Site Restoration Plan shall include the following, but not limited to:
o Consent letter from the concerned Wereda Administration for the land to be used as a
disposal site;
o A site plan showing the location and extent of the proposed spoil disposal site and
access road to the site for approval by the Engineer prior to commencement of spoil
disposal activities at the proposed site;
o Details of all landholdings and existing land use and land cover types;
o Details of the land acquisition plan including the compensation measures
implemented through a Compensation Committee;
o Measures which will be taken to minimise soil erosion caused by the access road;
o Details of the construction method and drainage system for the access road;
o Measures which will be taken to reinstate the disposal site and access road for
agriculture, if the site was previously used for this purpose;
o A schedule of landscaping, levelling and re-instatement of the site.
 When spoil disposal activities at approved sites are completed, the Contractor shall:
o Propose restoration and/or landscaping measures for approval by the Engineer. The
restoration measures shall include surface shaping, grading and compacting so as to
prevent stagnation of water;
o Provide easy access to people and animals for agricultural use or grazing;
o Spread with topsoil of at least 5cm thick and planting with appropriate grasses and
tree species in order to prevent erosion and slope instability;
o Restore the sites to a productive state with an improved visual appearance.
o Implement grassing and tree planting at the spoil disposal sites according to the
specifications shown in Clauses 9605 and 9606 or to the instruction of the Engineer in
consultation with the concerned Wereda administration, WLEPO or Natural
Resources Development Department.
1605 Soil Erosion Control
(a) General
The Works shall consist of temporary control measures as described in the Contract or required by the
Engineer during the process of the Works to control soil erosion and water pollution by use of berms,
dikes, silt fences, brush barriers, dams, sediment basins, filter mats, netting, gravel, mulches, grasses,
slope drains and other erosion control devices or methods. Appropriate control measures will be
required to avoid emission of a high concentration of sediments into wetlands, swampy areas and
other particular sensitive areas.
The temporary erosion control provisions shall be coordinated with permanent erosion control
measures to ensure economical, effective and continuous erosion control throughout the period of the
Works.
The Contractor shall provide an adequate cross sectional area to drainage structures to allow
sufficient passage for the discharge and shall put energy dissipaters, where necessary, for safe
disposal of the discharge.
The Contractor shall protect slopes with stabilising structures such as V-cut surface drainage behind
the top of cut slopes and cut off drains; retaining walls; wire basketry; gabions; other physical
structures including check dams; mitre drains; and other energy dissipating structures such as chutes
and cascades. The Contractor shall also implement bioengineering techniques to protect and stabilise
unstable slopes and shall also use appropriate local varieties of grass species, especially grasses
which are multi-purpose, (eg Vetiver Grass), together with physical engineering measures as soon as
possible after completion of the works. Cut-off drains shall be installed above cut slopes.
The Contractor shall rehabilitate existing roadside gullies and landslides at particular locations and
also other places outside the RoW, if accepted and approved by the Engineer and the Employer that
these gullies could impact on the road pavement.
The Contractor shall pave/line roadside drains, depending on the prevailing conditions such as the
nature of the soil, gradient/slope of the area, and other factors; and construct all energy-dissipating
structures at all drainage outlets and discharge points. The Contractor shall provide cross drainage
structures as frequently as possible to reduce the amount of flow from side ditches and to channel the
flood water into the nearest stream without scouring the side walls.
(b) Construction
A schedule of proposed temporary (and permanent) soil erosion control Works shall be developed by
the Contractor at the commencement of the Contract, in consultation with the Engineer and to his
satisfaction.
The Contractor shall carry out (and maintain) temporary erosion control to prevent soil erosion that will
adversely affect construction operations, damage adjacent properties, or cause contamination of
adjacent streams or other watercourses, lakes, ponds, swamps or other areas of water impoundment.
Such Works may involve construction of temporary berms, dikes, dams, sediment basins, slope drains
or the use of temporary mulches, mats, seeding or other control devices or methods as necessary to
control erosion. The slopes of cuttings and embankments shall be seeded and mulched as the work
proceeds, to the extent considered desirable and practicable by the Engineer.
The Contractor shall provide an adequate cross-sectional area to drainage structures to allow
sufficient passage for discharge and shall also minimise the effect of discharge from structures on their
downstream side in the form of gullies as shown on the Drawings. Thus, the Contractor shall
introduce energy dissipaters for safe disposal of the discharge along the watercourse on the
downstream side of the structure as shown on the Drawings.
The Contractor shall grass all embankments and cut slopes susceptible to erosion with appropriate
grass species (eg Kikuyu Grass) and shall ensure the survival of the grasses before handing over to
the Employer.
Temporary erosion control shall include construction outside the RoW where such work is necessary
as a result of the road works, such as borrow pits, quarry operations, haul roads and equipment
storage areas.
The Contractor shall incorporate all permanent erosion control features (as described in the Contract)
into the Works at the earliest practicable time, as outlined in the work schedule, to minimise the need
for temporary erosion control measures.
Where erosion is a problem, clearing and grubbing operations shall be so scheduled and performed to
enable grading operations and the construction of permanent erosion control features to follow
immediately thereafter if conditions permit. Otherwise, temporary erosion control measures may be
required between successive construction stages.
The Engineer will limit the area of clearing and grubbing, excavation, borrow and embankment
operations in progress commensurate with the Contractor’s capability and progress in keeping the
finished grading, mulching, seeding and other permanent erosion control measures current and in
accordance with the schedule of works. In the event that seasonal limitations make such coordination
unrealistic, temporary erosion control measures shall be taken immediately to the extent feasible and
justified.
The Engineer may increase or decrease the amount of surface area of erodible material to be exposed
at any one time by clearing and grubbing, excavation, borrow and fill operations as determined by the
Engineer’s analysis of project conditions.
In the event that temporary erosion control measures are required due to the Contractor’s negligence,
carelessness or failure to install permanent controls as part of the Works scheduled or ordered by the
Engineer, such Works shall be carried out by the Contractor at the Contractor’s own cost.
1606 Preservation of Trees and Shrubbery
(a) Preservation
All trees and shrubbery which are not specifically required to be cleared or removed for construction
purposes shall be preserved and shall be protected from any damage that may be caused by the
Contractor’s construction operations and equipment. Special care shall be exercised where trees or
shrubs are exposed to damage by construction equipment, blasting, excavations, dumping, chemical
damage, or other operations; and the Contractor shall adequately protect such trees by use of
protective barriers or other methods approved by the Engineer. The removal of trees or shrubs shall
be permitted only after prior approval by the Engineer.
The layout of the Contractor’s construction facilities such as workshops, warehouses, storage areas,
and parking areas; location of access and haul routes; and operation in borrow and spoil areas, shall
be planned and conducted in such a manner that all trees and shrubbery not approved for removal by
the Engineer shall be preserved and adequately protected from either direct or indirect damage by the
Contractor’s operations.
Except in emergency cases or when otherwise approved by the Engineer, trees shall not be used for
anchorage. Where use for anchorage is approved, the trunk shall be wrapped with a sufficient
thickness of approved protective material before any rope, cable, or wire is placed.
The Contractor shall not locate campsites, material sites and detour roads in forest areas, unless
specific prior approval is granted in writing from the regional/local Forestry Department. Clearance of
vegetation shall be confined to what is absolutely necessary and the Contractor shall take maximum
care not to cut any endangered and indigenous tree species (eg Abash Tid (Juniperus procera), Kosso
(Hagenia abyssinica), Wanza (Cordia Africana), and Zigiba (Podocarpus gracilior)) which may include
large individual trees located along the roadside.
(b) Repair or Treatment of Damage

The Contractor shall be responsible for the cost of the repair of damage to trees and shrubs caused by
the Contractor’s operations. The term “damage” shall include, without limitation, bruising, scarring,
tearing, and breaking of roots, trunk or branches. All damaged trees and shrubs shall be repaired or
treated without delay. The Engineer will determine the method of repair or treatment to be used for
damaged trees and shrubs as recommended by an experienced horticulturist or tree surgeon provided
by the Contractor. All repairs or treatment of damaged trees shall be performed under the direction of
an experienced horticulturist or tree surgeon provided by the Contractor.
(c) Replacement
Trees or shrubs that, in the opinion of the Engineer, are beyond saving shall be removed and replaced
early in the next planting season. The replacement shall be of the same species, or other approved
species, and of the maximum size that is practicable to plant and sustain growth in the particular
environment. Replacement trees and shrubs shall be staked, watered and maintained for a period of
one (1) year. Any replacement tree or shrub that dies shall be removed and replaced, as directed by
the Engineer, with such replacements being maintained for a period of one (1) year from the date of
replacement.
Trees and shrubs that are outside the areas of road clearing and widening, borrow pits, quarry
sources, detours and diversions, camp sites and other construction material sources should be
preserved. Tree species which are removed and have no ownership (and for which the Employer is
not to pay compensation) shall be replanted or replaced. The Contractor shall also replace, at his own
cost, trees or shrubs which have inadvertently been removed by the Contractor outside the road
construction limits that could have been saved during construction works.
The Contractor shall compensate for the loss of mature trees by planting at least 10 new seedlings for
every tree that is removed. The Contractor shall also manage their growth until they reach
approximately 1.5 metres high before handing over to the Employer or Local Authorities as directed by
the Engineer. The Contractor shall execute such plantations together with the local Department of
Agriculture or Forestry Department for the identification of species of trees to be planted, spacing and
planting locations, and shall make arrangements for the successful implementation of the replacing of
trees. The Engineer, in collaboration with the local Forestry Department and WLEPO will approve and
accept all plantation works.
The minimum distance between trees (centre to centre) ranges from 500mm to 750mm depending
upon the tree species and other local conditions. The Contractor shall seek technical assistance from
the local Forestry Department as to the plant species, spacing, location and other requirements.
Regarding location for plantations, priority should be given for the beautification of roadsides or
planting within the road reserve for maintaining the RoW width. In the event that the Contractor is
unable to undertake this particular work item, a local sub-contractor should be hired by the Contractor
to undertake this work as per the specifications.
Only acceptable sizes and species of indigenous trees will be considered for approval. The Engineer,
in collaboration with the local Forestry Department and the WLEPO, will approve the trees for planting.
The Contractor shall make the construction Workforce aware that they shall not cut down trees for any
purpose without prior approval of the Engineer and local Forestry Department. No indiscriminate
cutting down of trees, involvement of any trade activities or illegal transporting of forestry products by
the Contractor’s workforce will be permitted.
The Contractor shall prepare and file for future review by the Engineer and the Employer, a record of
the exact number of different tree species to be removed during the development of materials sites;
detour and access road construction; campsites; and stockpiling areas, in the presence of the
Engineer and Forester from the Local Forestry Department. Site photographs shall be taken before
starting site clearing works and shall be kept and filed as an official document for the future review by
the Engineer and the Employer.
1607 Prevention of Water Pollution
(a) General
The Contractor’s construction activities shall be performed by methods that will prevent the entry, or
accidental spillage of solid matter, contaminants, debris, and other pollutants and wastes into flowing
streams, flowing or dry watercourses, lakes, and underground water sources. Such pollutants and
waste products include, but are not restricted to, refuse, garbage, cement, concrete, sanitary waste,

industrial waste, radioactive substances, oil and other petroleum products, aggregate processing
tailings, mineral salts and thermal pollution.
Dewatering works for the foundations of structures, or earthwork operations adjacent to, or
encroaching on streams or watercourses, shall be conducted in a manner to prevent muddy water and
eroded materials from entering the streams or watercourses by the construction of intercepting open
drains, bypass channels, barriers, settling ponds, or by other means approved by the Engineer.
Excavated materials or other construction materials shall not be stockpiled or deposited near or on
stream banks, lake shorelines, or other watercourse perimeters where they can be washed away by
high water or storm runoff, or can in any way encroach upon the watercourse itself.
Increases in turbidity in a stream or other bodies of water that are caused by construction activities
shall be strictly controlled. When it is necessary to perform the required construction work in a stream
channel, the turbidity may be increased, as approved by the Engineer, for the shortest practical period
required to complete such work. The required construction work may include such work as diversion of
a stream, construction or removal of cofferdams, specified earthworks in or adjacent to a stream
channel, pile driving, and construction of turbidity control structures. Mechanised equipment shall not
operate in flowing water except as necessary to construct crossings or to perform the required
construction.
Waste water from aggregate processing, concrete batching, or other construction operations shall not
enter streams, watercourses, or other surface waters without the use of turbidity control methods such
as settling ponds, gravel-filter entrapment dikes, approved flocculating processes that are not harmful
to fish, recirculation systems for washing of aggregates, or other approved methods. Any such waste
water discharged into surface waters shall contain the least concentration of settleable material
possible. For the purpose of this Specification, settleable material is defined as that material which will
settle from the water by gravity during a one hour quiescent detention period.
Under no circumstances shall the Contractor dispose of used oils onto the soil or into water resources.
The oils shall be collected in a suitable manner and disposed of safely, as per the country’s law on
pollution control, or shall be collected in a suitable manner and the Contractor shall make his own
arrangements to dispose of the oils in a nationally accredited Oil Processing Company in charge of the
safe disposal of used oil from different sources.
Activities under Clause 1209 shall be applicable under this Clause.
(b) Compliance with Laws and Regulations

The Contractor shall comply with the prevailing versions of all applicable Ethiopian laws, orders,
regulations, and water quality standards concerning the control and abatement of water pollution.
These include:
 Proclamation on Environmental Pollution Control, No. 300/2002 (or superseding versions)

which is mainly based on the right of each citizen to have a healthy environment and which
states that the “polluter pays” principle shall apply to all persons;
 Proclamation on Ethiopian Water Resources Management, No. 197/2000 (or superseding
versions) which provides legal requirements for Ethiopian water resources management,
protection and utilisation; and ensures that water resources of the country are protected and
utilised for the highest social and economic benefits; to follow up and supervise that they are
duly conserved; ensure that harmful effects of water use are prevented; and that the
management of water resources is carried out properly.

1608 Abatement of Air, Dust, Noise and Light Pollution

The Contractor shall inspect and service all access/haul routes, construction vehicles, production
plants and other construction machinery and equipment, to the satisfaction of the Engineer, so that
their emissions shall not pollute the air. Parts of the Crusher Plant from where dust emanates shall be
covered to reduce dust emissions from the construction sites. Access roads and detours shall be
watered at least three (3) times a day at reasonable times of the day during the dry season. The
Contractor shall locate material production plants such as aggregate crushers, concrete and asphalt
plants away from settlement areas, hospitals and schools.
The Contractor shall avoid burning of materials such as tyres, plastic, rubber products or other
materials that create hazardous smoke, smog or toxic odours that pollute the air quality.
The Contractor shall safely dispose of all sanitary and other waste at all camps and sites in a manner
approved by the Engineer. This action shall not result in any form of soil or water pollution or hazard
to human or animal health. The Contractor shall take all reasonable precautions to prevent spillage
and leakage of materials to avoid polluting soil and water resources. The measures shall be
implemented in an effective way throughout the life of the contract.
The Contractor shall be responsible, at his own cost, for cleaning up any pollution caused by his
activities, to the satisfaction of the Engineer, and the payment of full compensation to those affected by
the Contractor’s activities.
(a) Abatement of Air Pollution

The Contractor shall comply with applicable Ethiopian laws and regulations concerning the prevention
and control of air pollution. Notwithstanding the above, in conducting construction activities and the
operation of equipment, the Contractor shall utilise methods and devices as are reasonably available
to control, prevent and otherwise minimise emissions or discharges of air contaminants.
The emission of dust into the atmosphere shall be strictly controlled during the production, handling,
and storage of concrete, asphalt and road aggregates; and the Contractor shall use such methods and
equipment as are necessary for the collection and disposal, or prevention, of dust during these
operations. The Contractor’s methods of storing and handling cement and pozzolans shall also include
means of eliminating atmospheric discharges of dust.
Equipment and vehicles that show excessive emissions of exhaust gases due to poor engine
adjustments or other inefficient operating conditions shall not be operated until corrective repairs or
adjustments are made.
Burning of materials resulting from the clearing of trees and brush, combustible construction materials
and rubbish will be permitted only when atmospheric conditions for burning are considered favourable
and when authorised by the Engineer. In lieu of burning, such combustible materials may be disposed
of by other methods as provided in Clause 1611. Where open burning is permitted, the burn piles
shall be properly constructed to minimise smoke and in no case shall unapproved materials such as
tyres, plastics, rubber products, asphalt/bituminous products, or other materials that create heavy
black smoke or nuisance odours, be burned.
Dust nuisance resulting from construction activities shall be prevented in accordance with the
requirements of Clause 1608(b).
(b) Dust Abatement

During the performance of the work required by this Specification or any operations appurtenant
thereto, whether within the RoW provided by the Employer or elsewhere, the Contractor shall furnish
all the labour, equipment, materials and means required; and shall carry out proper and efficient
measures wherever and as often as necessary to reduce the dust nuisance and to prevent dust which
has originated from the Contractor’s operations from damaging crops, orchards, cultivated fields and
dwellings, or causing a nuisance to persons. The Contractor will be held liable for any damage
resulting from dust originating from the operations under this Specification on the RoW or elsewhere.
The Engineer shall direct the sprinkling of water, or other measures for dust abatement where
necessary, to obtain adequate control. In particular, in towns and villages, water sprinkling will be
required as often as necessary to reduce the dust nuisance.
To reduce the dust problem the Engineer may direct the Contractor to install temporary speed limit
traffic signs on those sections of the road where dust development is unacceptable.
(c) Noise Abatement

The Contractor shall comply with applicable Ethiopian laws, orders, and regulations concerning the
prevention, control and abatement of excessive noise.
Blasting, the use of jack hammers, rock crushing, or other operations producing high intensity impact
noise may be performed at night only upon approval of the Engineer.
(d) Light Abatement

The Contractor shall exercise special care to direct all stationary floodlights to shine downwards at an
angle less than horizontal. These floodlights shall also be shielded so as not to be a nuisance to
surrounding areas. No lighting shall include a residence in its direct beam.
The Contractor shall be responsible for correcting lighting problems when they occur, as directed by
the Engineer.
1609 Preservation of Historical, Archaeological and Cultural Remains

The Contractor shall review and familiarise himself with the EIA and RAP reports, the country’s
relevant Laws on Archaeological and Cultural Resources, and shall comply with them, particularly
Proclamation on Cultural Heritage, No. 209/2000 (or superseding versions).
If the Contractor encounters archaeological, historical, and cultural sites; articles; artefacts; or other
archaeological and cultural remains; this shall immediately be reported to the Engineer. If items are
found at material sites, the Contractor shall look for and identify alternative sources of materials. If
found within the road reserve, the Contractor shall suspend the construction works at that particular
section and start construction works at another site until the location is assessed and final continuance
notice is received from the Engineer.
The Contractor shall identify and allow his machine operators to take part in an “Environmental
Awareness Workshop” which will be organised by the Contractor during the mobilisation phase of the
project to assist Machine Operators in the identification of archaeological artefacts and other
environmental and social factors encountered during excavation works.
The Contractor shall be aware of “Chance Findings” of any archaeological and historical remains and
prepare a plan in advance as to how to protect any artefacts and accommodate such delays. The
Contractor shall be legally responsible for providing the necessary protective measures.
1610 Pesticides
Pesticides include herbicides, insecticides, fungicides etc.; surface disinfectants; animal repellents;
and insect repellents. Should the Contractor find it necessary to use pesticides in work areas of the
Contract, he shall submit his plan for such use to the Engineer for written approval.

The Contractor shall read and comply with all manufacturers requirements when using pesticides.
1611 Clean-up and Disposal of Waste Materials

Disposal of all waste materials described in the following sub-sections shall be only at
designated locations identified by the Contractor and approved by the Engineer.
(a) Clean-up
The Contractor shall, at all times, keep the construction area, including storage areas, free from
accumulations of waste materials or rubbish.
All waste water and sewage from offices, and residential and mobile camps, shall be piped to soak pits
or other disposal areas constructed in accordance with local regulations; and, where and when such
regulations require it, the Contractor shall obtain a permit or other appropriate documentation
approving the disposal methods being used.
All used fuels, oils, other plant or vehicle fluids, and old tyres and tubes shall be collected to a central
disposal point on a regular basis and disposed of as specified below.
All household, office, workshop and other solid waste shall be collected to a central disposal area on a
daily basis and disposed of in a manner approved by the Engineer.
Servicing of plant, equipment and vehicles shall, whenever possible, be carried out at a workshop
area. The workshop area shall be equipped with secure storage areas for fuels, oils and other fluids
constructed in such a way as to contain any spillages which may occur; and similar storage where
used fluids can be stored securely prior to their disposal.
When the servicing of plant, equipment and vehicles is carried out away from the workshop area, it
shall be done at locations and in such a manner as to avoid spillage and contamination of streams and
other drainage courses. Any spillages shall be cleaned up by either burning in-situ or collecting the
contaminated soils and burning them at a central disposal area, all to the satisfaction of the Engineer.
Prior to completion of the work, the Contractor shall remove from the vicinity of the work, all plant
facilities, buildings, rubbish, unused materials, concrete formworks and other similar materials
belonging to the Contractor or used under the Contractor’s direction during construction. All work
areas shall be graded and left in a neat manner conforming to the natural appearance of the
landscape as provided in Clause 1602.
Any residue deposited on the ground from washing out transit mix trucks or any similar concrete
operations shall be buried or cleaned up in a manner acceptable to the Engineer.
In the event of the Contractor’s failure to perform the above work, the work may be performed by the
Employer, at the expense of the Contractor; and the Contractor’s sureties shall be liable thereof.
(b) Disposal of Waste Material

The Contractor shall:
 Dispose of all sanitary and other wastes at all camps and sites, including, but not restricted to,
refuse, garbage, sanitary wastes, industrial wastes, oil and other petroleum products
(including bituminous products), safely and in such a way that will not result in any form of soil
or water pollution or hazard to human or animal health;
 Take all reasonable precautions to prevent spillage and leakage of materials with the potential
to pollute soil and water resources. The measures shall be implemented in an effective way
throughout the life of the camp sites;

 Be responsible, at his own cost, for cleaning up any pollution caused by his activities to the
satisfaction of the Engineer; and the payment of full compensation to those affected by the
pollutants;
 Dispose of all unnecessary material and spoil material at the appropriate sites approved by
the Engineer, on land not required for any activity by the local community for agriculture,
grazing or any other public services. Spoil materials shall not be disposed of on areas of
aesthetic value;
 Dispose of combustible materials by burying or burning, where burial or burning of such
materials is approved by the Engineer; or by removal from the construction area. Disposal of
non-combustible materials shall be by burying, where burial of such materials is approved by
the Engineer; or by removal from the construction area. Waste materials removed from the
construction area shall be dumped at an approved dumping site.
1612 Summary of Environmental Mitigation Measures

The Contractor shall adequately mitigate and reduce the negative impacts that the road construction
will have on the project, the physical environment and the affected communities by implementing the
following mitigation measures, which shall form part of the SESMP.
(a) Air Pollution

 Reduce dust from construction sites, access roads and diversion roads by watering, especially
when they are located in sensitive areas, towns and villages;
 Prevent generation of air pollutants by watering during crushing and screening of aggregates;
 Locate construction plants such as stone crushing plants away from (at least 1.5km)
settlement areas, health centres, hospitals and schools;
 Avoid burning of materials such as tyres, plastic, rubber products or other materials that create
heavy smoke and/or noxious odours;
 Avoid disposing of any volatile chemicals into the atmosphere;
 Ensure that any vehicles with an open load carrying area for transporting potential dust
producing materials have properly fitted side and tail boards. Materials having the potential to
produce dust should not be loaded to a level higher than the side and tail boards and should
be covered with a clean tarpaulin in good condition;
 Provide safety equipment such as goggles, masks and other protection measures for the
Workforce as needed.
(b) Noise Pollution

 Prevent the noisy operation of equipment such as crushing plants near noise sensitive and
settlement areas such as public health units, schools, religious institutions (churches,
mosques) etc.;
 Undertake construction activities that generate disturbing noise levels during conventional
working hours;
 Screen equipment producing high levels of noise when working near settlement areas, clinics
and religious areas;
 Minimise the use of explosives and promote a systematic blasting schedule;
 Provide safety equipment pertaining to noise, such as ear protection wear for the Workforce
as needed.

(c) Traffic and Other Safety Issues

 Institute traffic safety awareness programmes, specifically at schools and religious institutions;
 Pay particular attention to child safety during construction and operation;
 Reduce traffic speed through towns and villages to a maximum of 30km/h;
 Provide Rumble Strips at every position where speed is restricted;
 Introduce and maintain clear, understandable signage;
 Limit construction hours to reasonable daylight hours near towns/villages and near to religious
institutions, health units and schools;
 Divert traffic wherever possible away from construction areas;
 Pay special attention to level differences between roadway edges and accesses to public
property;
 Limit construction periods in town sections to the minimum time practical;
 In areas of limited RoW widths, check the structural integrity of buildings close to the road
prism for safety.
(d) Camp Sites

 Take maximum care in locating the camps, workshops and materials processing and storage
sites in such a way as to avoid environmentally or socially sensitive areas;
 Select the location of camps, workshops and materials processing and storage sites in
collaboration with the concerned local authorities, the Engineer and the Employer. They shall
only be established at locations approved by the Employer and the Engineer in collaboration
with local officials and community members;
 Locate campsites where rivers and other drainage patterns will not be threatened;
 Locate campsites in less productive areas at least 1km away from water resources including
springs, streams and rivers;
 The camp sites shall not be located close to residential areas, on fertile farmlands and
forested lands;
 Avoid erection of fences across footpaths and animal tracks;
 Provide alternative pedestrian routes, where these are interrupted;
 Labour crews shall provide/import their own materials and supplies (water and fuel) and not
rely on local enterprises;
 Exposed soils in the camp sites shall be regularly wetted to avoid dust;
 Photographs of the campsite shall be taken before the construction of any structure in order to
compare the level of environmental degradation before and after the establishment of the
campsite and to plan rehabilitation work. Any removal activities of trees for camping shall be
done in the presence of the Engineer and a Forester from the local Forestry Department;
 Provide health care services, potable water supply, garbage disposal and sanitation facilities
for the camps including imperviously lined septic tanks, and proper hazardous waste disposal
systems including the collection of used oils at workshops;
 Dispose of all waste from camps in designated and authorised places;
 Carefully handle hazardous substances such as fuel, oil, lubricants, bituminous products and
cement during transport, storage and dispensing of the substances to avoid spillage and
environmental pollution risks;
 Limit the use of flammable materials in storage yards and buildings. All flammable materials
should be suitably labelled;
 Maintain proper management and discipline in the camps;
 Take all necessary measures and precautions to avoid any nuisance or disturbance to local
inhabitants arising from the execution of works;
 On contracts where the campsite shall be vacated and demolished at the completion of the
contract, the sites shall be reinstated to their original state. The reinstatement activities shall
include stockpiling the topsoil during camp construction, removing all concretes/slabs and all
scrap metals from the workshops, loosening the compacted soils, and spreading of top soil;
 Planting of appropriate tree seedlings in camp yards for beautification purposes.
(e) Quarry Sites, Borrow Areas and Diversion Roads

 Select quarry and borrow sites away from settlement and environmentally sensitive areas after
the approval by the Engineer, Employer and Local Authorities;
 Do not select quarry and borrow sites near or in river beds;
 Do not establish quarries and borrow pits in forest areas;
 Maintain diversion roads within the RoW as much as possible;
 Install cut-off drains above cut slopes/excavation to divert sheet runoff;
 Dissipate energy in drains and at discharge points;
 Make use of machinery/vehicles that are in a good state of repair;
 Limit operational hours to reasonable daylight hours near to towns/villages;
 Secure operational areas to prevent animal and human accidents;
 Dispose of all unsuitable material in the reshaping and landscaping of borrow areas during
rehabilitation;
 Cut slopes in borrow areas should be battered to stable slopes;
 Exposed soils at access roads and diversion roads should be regularly wetted to avoid dust;
 Reinstate all quarries, borrow sites and access roads after the completion of the road
construction works. Any material sites shall not be left open unless otherwise approved by the
Engineer and the Employer upon request from local people to have the sites open
permanently. The reinstatement work for borrow pits and quarries shall include dumping
unnecessary materials from excess cuts, landscaping/levelling/shaping, spreading the topsoil
uniformly over the surface, constructing spillways in areas that are deep enough to hold water
and by erecting barriers all around the area to prevent accidents to animals and humans. The
reinstatement work for access roads shall include preservation of the top soils and stockpiling
the top soils; removing the applied selected/foreign materials; loosening the compacted soils
and spreading the top soil. The reinstatement works, in general, shall include the following
activities:
o Taking photographs of the proposed borrow areas, quarry sites and diversion roads
before the commencement of the works;
o Taking lists of all tree species found in the proposed quarry sites, borrow areas and
diversion roads; and the exact number of trees to be affected in the presence of the
Engineer and a Forester from the Wereda Forestry unit;
o Preserve top soils for later use to refill borrow sites and quarry areas and avoid the
mixing of top soil with sub-soil;

o After reinstating, plant appropriate indigenous tree species or grasses to recover the
original vegetation and to improve the ecological and aesthetic value of the sites;
o Provide suitable drainage to prevent ponding of stagnant water in quarry and borrow
sites to reduce the risk of malaria and limit possible mosquito breeding sites.
(f) Slope Instability and Soil Erosion

 Remove all loose materials from cut faces;
 Limit disturbance to natural vegetation above cut slopes;
 Install stormwater cut-off drains above cut and fill slopes;
 Install stormwater cut-off drains above cut and fill slopes wherever surface erosion is
anticipated;
 Dissipate run-off energy in channels/drains and at discharge points;
 Pave roadside drains with slope gradients >5% and construct all energy-dissipating structures
at the drainage outlets and discharging points;
 Protect unstable slopes with stabilising structures such as retaining walls, wire basketry and
gabions as permanent installations on slopes that could be at risk;
 Provide riprap, grassing on erosion-prone slopes of high embankments and fill areas, toes and
banks of the streams to avoid/restrict erosion;
 Implement bioengineering techniques such as planting locally accepted varieties of grass
species together with physical engineering measures as soon as possible after completion of
the works to protect and stabilise cut slops and bare grounds;
 Apply rounding to the top of the slope and grassing on erosion prone slopes of high
embankments and fill areas, toes and banks of the streams to avoid/restrict erosion; and water
them until the grasses and trees are suitably established.
(g) Water and Soil Resources

 Avoid dumping of solid and liquid waste from construction areas and camps into farm lands,
streams, rivers and dry stream beds;
 Avoid the blockage of the natural flow of streams, rivers and wetlands;
 Install filters such as straw bales between the work areas and rivers/streams;
 Monitor water quality in rivers during construction activities;
 Maintain community access to rivers and streams (upstream of work areas) during
construction;
 Avoid the selection of quarry sites in river beds and river banks;
 Re-grass cut slopes and fill sections to avoid downstream sedimentation and water quality
deterioration;
 Avoid the polluting of soils, rivers or streams during concreting work from cement slag;
 Avoid the cleaning/washing of construction equipment and discharge of waste chemicals into
wetlands, streams and rivers. If such a problem occurs, the Contractor, at his own expense,
shall be obliged to restore the water to its original quality or potable standard;
Undertake the servicing of construction plant, equipment and vehicles at workshop areas. The
workshop areas shall be equipped with secured storage areas for fuels, oils and other
hazardous fluids. The storage should be constructed in such a way as to contain any spillages
which may occur. Similar storage should be constructed to store used fluids prior to their
disposal in a designated and authorised place. Waste oils from various plant and equipment
shall be collected in drums and sent to authorised oil reprocessing companies; and shall under
no circumstances be disposed of into wetlands, streams and rivers;
 Avoid conflicts with the water demands for domestic and livestock consumption; and give
priority to domestic and livestock consumption. Water from low discharge springs and
streams shall not be used and in such cases, the Contractor shall fulfil his water requirements
by developing his own water sources;
 Avoid locating camp sites near water sources and ground water recharging areas;
 Handle explosives and residue of fuel carefully to avoid health risks and soil and water
pollution;
 Ensure that all existing stream courses and drains, within and adjacent to the site, are kept
safe and free from any debris;
 Officially hand over all developed water sources at any locations to the Wereda Water
Resource Office after completion of the construction work.
(h) Flora
 Avoid the location of quarry or borrow sites in areas where there is significant cover of
indigenous tree species;
 Confine the clearing of vegetation to what is absolutely necessary. All trees and shrubs which
are not required to be cleared or removed for construction purposes should be protected from
any damage that may be caused by construction operations and equipment;
 Do not locate campsites, quarries, borrow pits and diversion roads in natural forest areas;
 Inform and liaise with local communities concerning trees and other plants that are at risk;
 Allow farmers adequate time to harvest their trees and/or crops before clearing;
 Transplant trees which are transplantable;
 Take maximum care to avoid the cutting of endangered indigenous tree species;
 Avoid the storing of fuels and chemicals under trees;
 Avoid the parking of vehicles under trees;
 Ensure that the construction Workforce does not cut down trees for any purpose without prior
approval from the Engineer and the local Forestry Department;
 Plant at least 10 new indigenous seedling species for each indigenous tree removed as part of
the construction works; and water them until the local Forester approves that they can grow
independently;
 Take photographs of the construction sites before commencing the clearing operations and
retain them as official documents in a separate folder;
 Strictly forbid the Workforce from deliberately cutting down trees and becoming involved in
any trade activities or illegal transport of forest products. The Contractor shall take
responsibility for any such misbehaviour by the Workforce.
(i) Fauna
 Forbid the workforce from deliberately killing wild animals;
 Maintain roadside trees and other vegetation that may serve as wildlife habitats, including
nesting places for birds;
 Abstain from encroaching into areas of wildlife habitats and other sensitive areas;

 Restoration of affected areas (eg quarries, borrow pits and access roads to those sites)
through replanting programmes;
 Install warning signs and speed control measures at animal crossing sites;
 Create awareness among drivers to give priority animals crossing the road and refrain from
chasing the animals away;
 Ensure that drivers are aware that they should limit the use of headlights when encountering
nocturnal animals during the night time and give priority to such animals in such
circumstances, and where safety measures permit, such lights should be dimmed or turned
off to allow the animal to cross the road.
(j) Farmland
 Campsites, quarries and borrow pits shall not be located on fertile farmland and shall be
restricted to less productive areas;
 Ensure that farmers have access to remaining lands during clearing operations;
 Ensure that diversion roads are not established in productive farmland and limit the diversions
to within the RoW;
 Abstain from dumping any spoil from construction activities onto farmland unless requested to
do so by the farmers;
 Separate topsoil from sub-soil and preserve top soil for later use;
 Reinstate all the farmland temporarily taken for various activities of road construction.
Reinstatement shall include stockpiling the top soil, removing any concrete or foreign
materials, loosening the compacted soil, landscaping/levelling/shaping and re-spreading the
stockpiled topsoil uniformly over the surface. The level of reinstatement shall be approved by
the Engineer to the satisfaction of the land-holders.
(k) Crossing Structures, Access Roads and other Services

 Provide separate crossing structures or access roads to individual houses on up-slopes and
social facilities;
 Market places shall not be used for permanent or temporary storage of construction materials;
 Water pipes shall not be blocked;
 Electric and telephone lines shall not be disrupted;
 Noisy operations shall not be undertaken near schools and religious places.
(l) Culverts and Bridges

 Install run-off filters, such as straw bales, between work areas and rivers/streams;
 Where possible, construct during the dry season;
 Prevent the disposal of any chemicals and fuels into streams and rivers;
 Where possible, maintain traffic flow during construction;
 Where diversion roads are required, rehabilitate the affected areas to a productive state after
completion by removing the pavement, loosening the compacted soils using rippers and re-
spreading the topsoil.

(m) Labour Issues

 Recruit, wherever possible, labour from the local community, giving priority to people affected
by the project;
 Ensure that child labour is not practiced, in accordance with Clause 1616 (b);
 Ensure that skills training and transfer is continuously undertaken throughout the duration of
the project;
 Labour crews should provide/import their own materials and supplies (water and fuel) and not
rely on local enterprise;
 Arrange for the provision of sufficient supply of suitable food at reasonable prices for all the
Contractor’s staff, Workforce, and Sub-Contractors for the purpose of, or in connection with
the Contract;
 Provide public information dissemination prior to, and during construction period;
1613 Health, Safety and Accidents

The Contractor shall comply with all Ethiopian laws related to health and safety provisions and shall
furnish, and cause to be used, such additional safeguards, safety devices and protective equipment as
the Engineer or any competent authority may determine to be reasonable and necessary to protect the
life and health of project staff and employees.
The Contractor shall take all measures and precautions necessary to ensure, so far as is reasonably
practicable and to the satisfaction of the Engineer, the health, safety and welfare of the Contractor’s
employees including those of his Sub-Contractors, the Engineer’s site staff, and all other persons
entitled to be on the Site. Such precautions shall include those that, in the opinion of the Engineer, are
reasonable to prevent unauthorised entry onto the Site and to protect members of the public from any
activities under the control of the Contractor. The Contractor shall, in collaboration with the local health
office, provide medical staff; first aid equipment and stores; sick bays; and a suitable ambulance
service at the camps, housing, and on the Site at all times throughout the period of the contract.
The Contractor and employees; the Sub-Contractors and employees; staff of the Engineer; and any
other persons authorised by the Contractor to be on the Site, shall comply in every respect with the
provisions of any statutory requirements as may be applicable to the Works in respect of health, safety
and welfare.
The Contractor’s personnel shall receive education related to safety procedures and emergency
response plans associated with their task.
At least thirty (30) days prior to commencement of the civil works, the Contractor shall prepare and
submit a Health and Safety Management Plan (HSMP) for the project aimed at minimising illness and
accidents among the Workforce, staff of the Engineer and the public during the construction period;
and implement the plan after approval by the Engineer and final acceptance by the Employer. The
HSMP shall clearly describe reasonable steps that must be taken by the Contractor to eliminate risks
to health and safety of the project workers and the public in the project impact area so far as is
reasonably practical. If it is not reasonably practical to eliminate risks to health and safety, the
Contractor shall minimise those risks as far as reasonably practical. The HSMP shall be included in
the Health and Safety Manual which shall be prepared and submitted to the Engineer for review and
approval. The Manual shall comply with the requirements of national health and safety legislation.
The approved HSMP shall clearly indicate the Contractor’s responsibilities with regard to health and
safety issues and describe the steps to be taken by the Contractor to eliminate or minimise risks to
health and safety which include, but not limited to the following:

 Designation of a competent and qualified Health and Safety Officer approved by the Engineer.
The Officer shall be an experienced professional reporting directly to the Contractor and shall
have specific knowledge of all pertinent safety regulations and legislations in force in Ethiopia,
including prior experience and responsibility for health and safety on similar Sites. The Officer
shall also:
o Have workable knowledge in Social and Environmental aspects of road projects and
shall liaise regularly with the Ministry of Labour and Social Affairs to address the
employment, occupational health and safety issues; and to comply with the country’s
laws and regulations.
o Be empowered to act upon the receipt of instructions from the Engineer in respect of
the health and safety of personnel on Site and the safe execution of the Works.
o Manage the Occupational Health and Safety programme and report on all health and
safety issues and incidents to the Engineer in a format(s) to be agreed with the
Engineer. This will include the management of health and safety problems on site,
advice on all matters affecting the health and safety of the Workforce and on
measures to be taken to promote health and safety issues. The Contractor shall
report such activities in the Monthly Progress Reports.
 Implementation of the necessary precautions for night works. To this end, the Contractor shall
do the following:
o Become familiar with the country’s safety laws and safety requirements for night time
working;
o Prevent a worker from working both day and night in a twenty-four (24) hour period;
o Provide the necessary lighting, including standby facilities in the event of failure that,
in the opinion of the Engineer, is adequate to ensure the safe execution of any Works
that are to be carried out at night. The Contractor shall provide adequate lighting
wherever work is being executed at night and shall provide, and install, any additional
lighting that the Engineer may require in order to gain access to, observe and
supervise the Works including any testing and examination of materials;
o Provide sufficient and suitable lighting to allow safe passage of vehicles during night
hours; including the illumination of potentially hazardous areas such as vertical drops,
excavations, restricted lanes, traffic diversion signs etc;
o Provide standard retro-reflective signs that can be seen at night;
o Provide occupational safety and health equipment and training to all site personnel.
No site personnel shall be allowed to work on the site without the required equipment
and training;
o Prevent blasting activities at night time, within sensitive sites such as parking areas
and in close proximity to schools, settlement areas, hospitals, and religious sites.
 The provision of protective clothing and safety equipment, including relevant information,
instruction, training and supervision as are necessary to ensure the health and safety of all
persons employed on or entering the Site in connection with the Works, including the staff of
the Engineer; all in accordance with the laws of Ethiopia. Such safety equipment and
protective clothing shall be of a high standard; approved by the Engineer before distribution;
and provided at approve regular intervals throughout the project. Such Safety equipment shall
include, but not limited to:
o Safety helmets;
o Protective footwear;
o Safety glasses;
o Welding goggles and other eye protectors;
o Ear protectors;
o Safety harnesses;
o High visibility reflective vests;
o Safety equipment for working over water;
o Rescue equipment;
o Fire extinguishers.
 Implement procedures that prevent any project worker or visitor from entering the work site
without appropriate protective equipment, relevant to the hazards to be expected during
specific work activities.
 Minimising the likelihood of malaria outbreaks by not creating temporary or permanent water
holding areas which favour mosquito breeding. The Contractor shall be prepared to avoid
possible health risks through environmental health and hygiene management of camp sites
and availing clinics, chemically treated mosquito nets and medicines for the Workforce. The
Contractor shall, as soon as is practical, restore/reinstate borrow pits and quarry areas to
avoid breeding sites for mosquitos.
 The provision and maintenance of a suitably equipped and staffed clinic in the main camp site,
with all necessary medication; and first aid kits at all working sites, to the satisfaction of the
Engineer and with the following requirements:
o The clinic shall be run by a Medical Doctor appointed by the Contractor and should
have at least one (1) nurse with at least two (2) years of experience in a similar
position.
o The clinic shall be built and equipped to the approval of the appropriate medical
authorities and to the satisfaction of the Engineer.
 First aid kits shall be well-stocked, and shall be provided and maintained at suitable locations
on the Site, in the vehicles of the Contractor and supervisory staff and in the vehicles of the
Engineer. These kits shall be regularly replenished after use or if supplies are out of date.
 The Contractor shall provide a stock of medicines and medical equipment of scope, quantity
and standard deemed adequate by the appropriate medical authorities; and shall keep such
stock and equipment replenished and in a good order.
 The services shall be provided to the Contractor’s staff including those of the Sub-Contractors,
the Engineer’s site staff, and all other persons entitled to be on the Site.
 The health services shall be available at all times when there is work activity on the site.
 The execution of suitable arrangements for ensuring safety and absence of risks to health in
connection with the use, handling, storage, transport and disposal of articles and substances.
Transportation of any material by the Contractor shall be in suitable vehicles which when
loaded does not cause spillage. All loads shall be suitably secured. Any vehicles failing to
comply with these requirements or any of the local traffic regulations and laws shall be
removed from the Site.
 Keeping the Site reasonably free from all unnecessary obstructions during the execution of the
Works. The Contractor shall store or dispose of any of his equipment and surplus materials;
and clear away and remove from the site any wreckage, rubbish or temporary works no longer
required.
 Storing, handling, and the use of explosives shall be undertaken with the utmost caution and
strictly in accordance with the statutory government regulations. The Contractor shall:
o Be responsible for the presentation of any unauthorised issue or improper use of any
explosive;
o Ensure that the handling of explosives shall be entrusted only to experienced and
responsible persons.
o Store explosives and chemicals under strict security at a safe distance from the road
and any inhabited premises.
o Give warning each time of his intention to blast and should station personnel on the
roads and elsewhere with flags, horns and whistles; and prevent persons, animals
and traffic entering the danger zone. To this end, the Contractor shall fulfil at least all
of the requirements under Clause 1210 of these Specifications.
 The provision and maintenance of the Contractor’s equipment in a safe working condition and
the adoption of methods of work that are safe and without risks to the health of any person
entitled to be on the Site.
 Ensure that the servicing and repair of all plant and vehicles of the project shall be carried out
in designated areas within the camps and not on the Site.
 The provision of suitable drainage and trimming of excavated parts in all quarries and borrow
pits to avoid ponding of water, to the approval of the Engineer.
 Ensure that the potential danger to the public (including pedestrians, all road users and
adjacent building owners and occupiers) is kept to an absolute minimum. All work sites are to
be clearly signposted and fenced; and if necessary, lit at night. Safe traffic control
arrangements including well-signed pedestrian routes shall be provided to avoid accidents.
 Adequate barricading of all open excavations to prevent any persons or animals from
accidentally falling into them. Any open excavation in the road carriageway or shoulder areas
shall, in addition, be marked at night with white painted drums (or similar) and red or amber
lamps, to the satisfaction of the Engineer.
 The provision and maintenance of access to all places on the Site in a condition that is safe
and without risk of injury.
 The provision of education to personnel of the Contractor related to safety procedures and
emergency response plans associated with their tasks.
 The provision of accommodation and amenities, as it may be necessary for all staff and
labour, including all fencing, water and electricity supply, sanitation, cookhouses, fire
prevention and fire-fighting equipment, air conditioning, cookers, refrigerator, furniture, and
other requirements.
 The provision of necessary arrangements for the transport of any of the Contractor’s
employees or family members who may die on site, to their place of burial.
 Minimisation of dust emissions by watering the road during construction at settlement areas
for the number of times per day prescribed by the Engineer; but at least three (3) times a day
in dry seasons.
 Strictly forbidding the use of liquor or drugs in whatever means or manner.
 Employment of qualified drivers and operators; provision of refresher training; promotion of
careful and responsible driving and operation; application of speed limits in settlements, on
open roads and through construction areas; and the application of strict measures on a driver
that violates the rules of safe driving.
 Implementation of appropriate measures for the prevention of, and protection against, fires on
the Site during the performance of the Works. In particular, the Contractor shall ensure that
charcoal burning activities are not carried out within any of the worksites. Any incidents of
charcoal burning or fire on the worksite shall be reported to the Engineer.
 The provision and maintenance of an adequate number of appropriate fire extinguishers at
suitable locations on the Site, in the vehicles of the Contractor and supervisory staff and in the
vehicles of the Engineer.
 Immediate notification to the Engineer of any serious accident that occurs on the road, within
the extent of the Works, which results in death, severe injury or hospitalisation of persons for a
period exceeding three (3) days. Although such information may initially be conveyed
verbally, the Contractor shall submit a detailed written report within twenty-four (24) hours of
the event. The report shall be in writing and it shall be supported by photographs. The
Contractor shall comply with any requirements in respect of reporting such serious accidents
to the statutory authorities.
 Record and report the details of any other accident or incident concerning health, safety and
welfare, or damage to property to the Engineer (and to the statutory authorities) if appropriate,
as soon as possible after its occurrence and in such a format as the Engineer may require.
The Engineer has the right to conduct any enquiry, either on Site or elsewhere, as to the
causes and consequences of any accident. The Contractor shall also keep a comprehensive
record of all accidents which occur on the road and shall make such records available to the
Engineer on request. In addition, the Contractor shall keep an ongoing register of all
accidents, incidents and fatalities which should include the time and date of the incident, the
people involved and impacted, the results of the investigation into the cause of the incident,
the corrective actions instituted aimed at preventing a similar incident from happening again,
whether or not the incident was reported to the Police and insurers, what compensation was
paid etc. Such a register should be provided to the Engineer and Employer on a monthly
basis.
 Provision of safety induction for all new staff and visitors to the project site. The safety
induction should outline the main hazards and safety mitigation features relevant to the site.
 The Health and Safety Management Plan (HSMP) shall include mandatory safety briefings of
all staff, workers and Sub-Contractors on a regular frequency, (eg on a weekly and/or monthly
basis). The HSMP shall stipulate what is required to be addressed in each of these types of
meetings and how they shall be attended and documented.
 Payment of compensation according to the laws of the country for loss or damage suffered as
a consequence of any accident or injury or disease resulting from the work of any person in
the employment of the Contractor or any Sub-Contractor.
 Provision of adequate water-borne sanitation, refuse collection and disposal complying with
the laws of Ethiopia and all local by-laws and to the satisfaction of the Engineer, for all houses,
offices, workshops, and laboratories erected on the campsite or other sites. No disposal shall
be allowed to the surface or water courses. Oils and greases shall be recycled or safely stored
for the handling and disposal by a licensed company dealing with such waste. Solid waste
shall be disposed of by burning or burial.
 Provision of an adequate number of suitable latrines and other sanitary arrangements at
locations where work is in progress. The Contractor shall ensure that they are regularly
cleaned and maintained in a hygienic state, all to the satisfaction of the Engineer and the
public health authorities of the area.
 Execution, in consultation with the appropriate public health authority, of appropriate measures
to control within the Site (including camp sites) mosquitoes, flies, pests and vermin. Such
measures shall include the application of suitable pesticides and chemicals to infested areas.

 Ensure that the Works are left in a safe condition if the Contractor should temporarily close
down his operations for seasonal or other reasons. The Contractor shall appoint one (1)
member of staff to be responsible for the safety of the Works throughout the shutdown period
and shall notify the Engineer of the name and contact telephone number of the responsible
person.
 Ensure that, when selecting campsites, there is limited, close interaction with the local
community.
 Ensure that all site staff and labour including all the employees of the Contractor, all Sub-
Contractors, staff of the Engineer, all truck drivers and crews delivering to the site are advised
of the dangers and impact of Sexually Transmitted Diseases (STDs) in general, and HIV/AIDS
in particular. To this end, the Contractor shall fulfil as a minimum, all the requirements under
Clause 1216 of these Specifications.
 The provisions of this Clause shall also apply to the Sub-Contractors of the Contractor, with
the necessary changes. The Contractor shall ensure that these provisions are included in all
sub-contracts placed by him.
1614 General STD and HIV/AIDS Prevention and Control Programme

The Contractor, through a Sub-Contractor (local NGO and/or firms that have adequate experience on
HIV/AIDS prevention and control programmes), shall implement the STD and HIV/AIDS prevention
and control activities at the project campsites and communities along the road corridor. The
procurement of the Sub-Contractor shall be done by the Employer and approved by the Engineer. The
Sub-Contractor shall be responsible for the implementation of all activities stipulated in the Terms of
Reference. The hiring of a Sub-Contractor shall be completed during the mobilisation period of the
project.
The Sub-Contractor shall work closely with the Contractor and also with the local community for the
implementation of the programme.
The Contractor shall pay the Sub-Contractor on an activity basis and also based on the action plan
submitted at the beginning of the project.
The Contractor, through the Sub-Contractor, shall prepare detailed and comprehensive monthly
reports and submit the reports to the Engineer. At the end of the project, the Contractor, through the
Sub-Contractor, shall prepare a detailed completion report for the HIV/AIDS prevention and control
activities and the report shall contain:
 The name of the NGO contracted;

 A rating of the performance of the NGO;
 Summary of activities carried out;
 A record of the number of people that participated from the Contractor’s staff and the
communities;
 An analysis of problems encountered, actions taken and lessons learned.
1615 Liaison with Communities and Local Authorities

The relationship between the project staff and the Local Communities, Government Officials and
Traditional Leaders is an important aspect that will either contribute to or detract from the overall
success of the project.

In all dealings with the Community and Workforce employed from within the Community, the
Contractor shall take due cognisance of the character, culture and circumstances of the Community;
and shall at all times endeavour to avoid the development of disputes and shall foster a spirit of
cooperation and harmony towards the project.
The Project Liaison Committee (PLC) shall be established as the primary mechanism of
communication with the Local Authorities and the Community. This Committee shall have a key role in
monitoring the overall impact of the project on the Community. The Contractor shall attend all
meetings of the PLC as may be reasonably required by the Engineer and shall provide adequate
information to the Committee in order for it to fulfil its responsibilities.
The PLC shall meet on a monthly basis and monitor Site activities against a basic check list that will
include the following:
 Is the required proportion of local participation in the Workforce being achieved?

 Is the required proportion of women in the Workforce being achieved?
 Is remuneration equal between men and women?
 Do all members of the Workforce have signed employment contracts and copies of their
conditions of employment?
 Are the wages being paid on time?
 Are members of the Workforce being required to work significant overtime?
 Have any disputes arisen between the Workforce and Contractor or Sub-Contractors?
 Are the HIV/AIDS programme activities aimed at the local population being implemented?
(especially related to behaviour change initiatives and stigma and discrimination issues)
 What are the corrections needed to reach the expected outcomes of the HIV/AIDS
programme?
 Are there any negative impacts from the development of the programme in relation to the local
communities and according to complaints and problems presented locally?
 What are corrective measures for any negative impacts of the HIV/AIDS programme?
 Are there any examples of benefits achieved from the project, presented and reported by the
local community and its representatives?
The above checklist shall provide the basis for the minutes of the PLC meeting. Completed HIV/AIDS
Monitoring Sheets related to the activities aimed at local communities shall be attached to the minutes.
The minutes of the PLC shall be attached to the minutes of the monthly Site meeting.
(a) PLC Representatives

Typical officials that would constitute the PLC are as follows, but not limited to:
 Contractor’s representative/Human Resource Manager;

 Contractor’s Health and Safety Officer;
 HIV/AIDS approved Service Provider (see Clause 1614);
 Representative of the Engineer;
 Representative of the Road Owner or Client Authority;
 Persons representing the Local Authorities and elected or appointed by the local inhabitants
(represented by women and men);
 Representatives from District Authorities such as Public Works and Housing, Health,
Education, Labour and Social Welfare (represented by women and men);

 Key persons elected or appointed by the local community (eg a nurse, teacher, religious
representative, local adviser, person locally responsible for social issues, etc).
(b) Public Meetings

At the commencement of the project, the Contractor shall hold public meetings in the main service
centres in the vicinity of the Site to advise the local business community and the public of employment
and business opportunities that will be available to them. These meetings shall be publicised at least
two (2) weeks in advance of the meeting through the local authorities and local media including radio
stations.
The procedures for the recruitment of skilled and unskilled workers, and procedures for the selection
of local suppliers and sub-contractors shall be explained at the meeting.
(c) Notices
The Contractor shall display a notice in a conspicuous place in the Site camp on a minimum A1-size
sheet, with 2 cm high lettering in English and Amharic with the following information:
 Start and end date of the Works contract;

 Brief description of the Works;
 Minimum age required for employment;
 Proportion of female workers required in the Workforce;
 Conditions of employment:
 Normal working hours including breaks;
 Wage rates for each class of worker in the Workforce;
 Details of any deductions, including for sick days;
 Date of payment of wages;
 Details of any benefits, including Workers Compensation Insurance; and provision of meals
and drinking water.
In addition to the above requirements, the Contractor shall provide each employee with the above
information printed on an A4 sheet in English and Amharic.
1616 Participation of Local Communities

The Contractor shall limit the utilisation of his permanently employed personnel on the Works to that of
Key Personnel and shall execute and complete the works using a temporary local Workforce
employed directly by the Contractor or Sub-Contractors to the extent that is practical and reasonable.
In addition, the Contractor shall employ staff and labour in the vicinity of the project. If adequate skills
are not locally available, the Contractor may recruit from elsewhere in Ethiopia. The Contractor shall
not recruit or attempt to recruit his staff and labour from amongst persons in the service of the
Client/Employer or the Engineer.
(a) Compliance with Labour Law

The Contractor shall comply in all respects with the Labour Law currently in force. The Contractor shall
ascertain from the Ministry of Labour, and shall strictly comply with, all the regulations, written or
otherwise, of the Ministry or any of his duly appointed representatives affecting the employment of any
class of local employee under the contract.

(b) Employment of Children

Children, as defined by Government regulation shall not be employed under any circumstances. The
Engineer and the Employer’s representative have the right to decide whether any labourer employed
by the Contractor or the Sub-Contractor is a child as defined by Government regulation and to refuse
to allow any such labour to be employed on Site.
(c) Sub-Letting of Works

The Contractor may sub-contract work reserved for labour-intensive methods to local contractors.
The hire of plant and equipment from persons or small local companies shall be deemed to be sub-
letting and hirers of plant and equipment shall be deemed to be “Sub-Contractors”.
(d) Responsibility of Sub-Contractors

The Contractor shall be responsible for determining the scope and extent of works to be included in
any particular sub-contract; the total number of sub-contracts let; and the time and duration, in such a
manner to facilitate the achievement of all objectives and principles pertaining to small contractor
utilisation and development as are stated or inferred in the provisions of contract.
(e) Selection of Sub-Contractors

The Contractor shall select local Sub-Contractors to participate in the project from applications
received following the public consultations. The Contractor shall implement a transparent selection
process based on provable credentials.
(f) Labour Sub-Contractors

Labour-only sub-contracts are expressly forbidden.
(g) Recruitment of Labour

The Contractor shall advise the Local Authorities in the vicinity of the project of the requirements of the
Workforce. This shall include a list of specific skills and experience required and an indicative
programme of recruitment.
The Community shall be advised through the Local Authorities, Local Community Leaders and at
public meetings of specific times when they should present themselves to the Contractor’s premises
for registration. The Contractor shall record the following information on each candidate:
 Name;
 Home address;
 Gender;
 Previous construction experience.
The Contractor shall request verification of this information from local authority representatives, to
confirm that all candidates are resident locally.
If the number of candidates for specific posts exceeds the number of job opportunities, the Contractor
shall select the Workforce by a ballot system in the presence of representatives of the Local Authority.
Female workers shall be recruited separately from male workers to ensure that the proportion of
women on the Workforce, specified in any particular contract, is achieved.
(h) Reporting
The Contractor shall provide a list of Key Personnel indicating the following criteria for presentation at
the monthly Site meeting:

 Nationality of each person;

 Gender of each person;
 Proportion of Ethiopian nationals;
 Proportion of women.
The Contractor shall provide a list of the Workforce indicating the following criteria for presentation at
the monthly Site meeting:
 Total size of the Workforce;

 Number of skilled and unskilled personnel;
 Total number of men;
 Total number of women;
 Proportion of women;
 Total number of local residents;
 Proportion of local residents;
 Total hours worked by men during the month;
 Total hours worked by women during the month;
 Proportion of total hours worked by women;
 Average number of hours worked per week by men;
 Average number of hours worked per week by women.
1617 Complementary Interventions

The Contractor shall implement Complementary Intervention activities specified in the Contract or by
the Engineer in liaison with the Wereda Development Committee, PLC and Local Communities.
Guidance on the implementation of Complementary Interventions is given in the prevailing version of
the ERA Low Volume Road Design Manual, Part C.

Except for the specific Pay Items specified in this Clause work performed as part of the obligation
within this Division shall not be paid separately and the cost thereof is deemed to be included in other
rates.
Item 16.01 Preparation of a Management Plans

a) Site Environmental and Social Management Plan (SESMP) .............................. Lump Sum (LS)
b) Health and Safety Management Plan (HSMP) .................................................... Lump Sum (LS)
The tendered rate shall include full compensation for the preparation and submission of draft plans to
the Engineer and the Employer; and the incorporation of any comments by the Engineer and the
Employer into the final document.
The SESMP shall include the item specified in Clauses 1603 and 1612.
The HSMP shall include the items specified in Clause 1613.
Payment of the lump sum tendered under sub-items 16.01(a) and (b) will be made after approval of
the final Plans has been received from the Engineer and the Employer.
This items shall make provision for any revisions required to the plans during implementation; and
shall not be paid separately.
Item 16.02 Provision of Occupational Health and Safety Equipment with Worker Training
............................................................................................................. Lump Sum (LS)
The provision of Occupational Safety and Health equipment shall include, but not limited to; protective
clothing; chemically treated mosquito nets; safety helmets; protective footwear; safety glasses;
welding goggles and other eye protectors; ear protectors; safety harnesses; high visibility reflective
vests; safety equipment for working over water; rescue equipment; and fire extinguishers. Training
shall be given by the Contractor to the Contractor’s staff including those of the Sub-Contractors, the
Engineer’s site staff and all other persons entitled to be on the Site to the satisfaction of the Engineer.
Payment of the lump sum tendered under this item shall be made, as follows:
 The first instalment (20% of the lump sum) shall be paid in the first payment certificate after
the Contractor has distributed the required Safety and Health equipment and provided the
required training to workers to the satisfaction of the Engineer;
 Subsequent instalments (60% of the lump sum) will be paid in instalments throughout the
contract based on a training schedule approved by the Engineer. Each payment shall include
the distribution and supply of the required Safety and Health equipment and the provision of
the required training to workers prior to the contract completion date;
 The final instalment (20% of the lump sum) shall be paid on the issuance of the “Taking over
Certificate” to the Contractor.
Item 16.03 Provision of a suitably equipped and staffed Clinic in the main construction
camp; and the provision of first aid equipment, kits and medical supplies, sick
bay and a suitable ambulance service at all camps on the site ..............................
............................................................................................................. Lump Sum (LS)
Payment of the lump sum tendered under this item shall be made in three instalments, as follows:
 The first instalment (80% of the lump sum) shall be paid in the first payment certificate after
the item is provided, erected, fitted or installed to the Engineer’s satisfaction;
 The second instalment (10% of the lump sum) shall be paid in the first payment certificate
after the value of all permanent work done, excluding escalations, exceeds one-half (½) of the
tendered amount;
 The third instalment (10% of the lump sum) shall be payable in the payment certificate which
follows the removal of all items from the site.
The payment for the lump sum tendered under this item shall be in full compensation for providing,
procuring, erecting, installing and/or fitting the item or service as may be required or specified for the
use of the item or service including replacements when defective; and all transport, handling and other
costs.
The tendered rate shall also include full compensation for the provision of stocks and medicines and
medical equipment of scope, quantity and standard deemed adequate by appropriate medical
authorities; and keeping such stock and equipment replenished and in a good order.
Item 16.04 Watering of the road under construction, temporary diversions, and access and
haul roads at settlement areas ........................................................... kilometre (km)
The unit of measurement of shall be kilometre. The measurement shall be the total of the sum of the
lengths of the road under construction, diversions, and access and haul roads watered once.
The tendered rate shall include full compensation for the supply, transport and application of the water.

Watering will be paid if it is performed in the dry season upon the Engineer’s Instruction and
satisfaction. Water required for the construction of temporary diversions and access and haul roads
will not be measured for payment.
Item 16.05 STD and HIV/AIDS Prevention and Control Programme

The cost of provision of all the STD and HIV/AIDS alleviation measures shall be paid under the
following Items in the Bills of Quantities (BOQ).
a) Preparation of action plans on STD and HIV/AIDS alleviation measures, provision of information
and educational materials, counselling and testing services and establishment and training of
peer educators and Anti-AIDS Committees ................................................ Provisional Sum (PS)
b) Percentage allowed for overhead and profit on item 16.05 (a).................................. Percent (%)
The provisional sum shall include but not be restricted to:
 Provision of educational materials, posters, leaflets, pamphlets, brochures and condoms to the
project staff and the host communities;
 Provision of Information, Education and Communication (IEC) campaign on STD and
HIV/AIDS including celebration of the “World HIV/AIDS Day’’ by the project staff and the host
communities;
 Provision of Voluntary Counselling and Testing services to the project staff and the host
communities and treatment of opportunistic infections;
 Provision of nutritional supplement for each of the project staff living with HIV/AIDS;
 Subsistence allowance, accommodation and office for the professional staff of the STD and
HIV/AIDS Sub-Contractor.
The provisional sum shall be paid by the main Contractor to the nominated Sub-Contractor in
instalments against outputs and activities of the action plan agreed between the Sub-Contractor and
the Contractor; and approved by the Engineer.
Payment of the Contractor’s overhead in Pay Item 16.05 (b) shall be paid in instalments as a
percentage of the Sub-Contractor’s invoice against outputs and activities of the action plan agreed
between the Contractor and Sub-Contractor and approved by the Engineer.
Item 16.06 Liaison with Communities and Local Authorities

a) Establishment and management of a Project Liaison Committee (PLC) approved by the Engineer
including the organisation of public meetings and project related notices to the Community
.................................................................................................................... Provisional Sum (PS)
b) Percentage allowed for overhead and profit on item 16.06 (a) ................................. Percent (%)
This item provides for a provisional sum for the establishment and management of a PLC and shall
include the provisions of Clause 1615.
Item 16.07 Complementary Interventions

a) Provision for the inclusion of complementary interventions to the contract as agreed and directed
by the Client .............................................................................................. Provisional Sum (PS)
b) Percentage allowed for overhead and profit on item 16.07 (a) ................................. Percent (%)
This item provides for a provisional sum for any complementary interventions that may be required by
the Employer as part of the Contract in consultation with relevant Wereda Development Committee,
and the PLC.
Division 1700: Overhaul

Work performed in haulage of material shall not be paid separately and the cost thereof is deemed to
be included in other rates.

Series 2000: Site Clearance
TABLE OF CONTENTS
DIVISION 2100: CLEARING AND GRUBBING ............................................................................................ 157
2101 Scope ........................................................................................................................................ 157
2102 Description of Work ................................................................................................................... 157
(a) Clearing .........................................................................................................................................157
(b) Grubbing .......................................................................................................................................157
(c) Ground Surface Level after Clearing and Grubbing .....................................................................157
(d) Conservation of Topsoil ................................................................................................................158
(e) Conservation of Vegetation ...........................................................................................................158
2103 Execution of Work ..................................................................................................................... 158
(a) Areas to be Cleared and/or Grubbed ............................................................................................. 158
(b) Trees ..............................................................................................................................................158
(c) Disposal of Material ...................................................................................................................... 158
DIVISION 2200: DEMOLITION, REMOVAL, DISPOSAL, STORAGE OR CLEANING OF EXISTING STRUCTURES AND
INSTALLATIONS 161
2201 Scope ........................................................................................................................................ 161
2202 Demolition of Structures............................................................................................................ 161
2203 Demolition of Existing Road Pavements ................................................................................... 161
2204 Cleaning of Existing Drainage Structures .................................................................................. 161
2205 Construction Requirements for Existing Public Utilities ............................................................ 162
(a) Disconnections .............................................................................................................................. 162
(b) Protection of Existing Public Utilities ........................................................................................... 162
(c) Relocation of Existing Public Utilities .......................................................................................... 162

Division 2100: Clearing and Grubbing
2101 Scope
This Division covers the clearing of the Site and grubbing necessary for the construction of the
permanent Works in accordance with these Specifications; and the removal and disposal of materials
resulting from clearing and grubbing. This work shall also include the preservation from injury or
defacement of all vegetation and objects designated to remain.
2102 Description of Work
(a) Clearing
Where directed by the Engineer, clearing shall consist of the removal of all trees, brush, other
vegetation, rubbish, fences and all other undesirable material including the disposal of all material
resulting from the clearing and grubbing to a maximum depth of 150mm, except for boulders.
It shall also include the removal and disposal of structures that obtrude, encroach upon or otherwise
obstruct the work and which can be cleared by means of a bulldozer of 22 tonne mass and flywheel
power of 270kW. This also includes the removal of signposts; the demolition and removal of paved
ditches; and the demolition and removal of any other masonry or concrete structures that obstruct the
work.
The moving of a certain amount of soil or gravel material may be unavoidable during the process of
clearing.
3
Clearing shall include the removal of all rocks and boulders less than 0.15m in size, which are
exposed or lying on the surface.
Any trees, structures or artefacts, either identified on the Drawings or noted on Site for care and
retention, shall be clearly marked off on the Site in a manner approved by the Engineer to avoid
accidental damage during construction operations. Should any such identified trees, structures or
artefacts be damaged inadvertently, or otherwise, the Contractor must report the same to the Engineer
in writing explaining any known reasons for the damage. Damage deemed to be caused by the
negligence of the Contractor shall be repaired at the Contractor’s cost.
(b) Grubbing
Where directed by the Engineer, all stumps and roots larger than 75mm in diameter shall be removed
to a depth of not less than 500mm below the subgrade level and a minimum of 300mm below the
cleared original ground level. Where the existing ground has to be compacted, all stumps and roots
including matted roots shall be removed to a depth of at least 200mm below the cleared surface,
except where otherwise specified or directed by the Engineer.
Except at borrow areas, the cavities resulting from the grubbing shall be backfilled with approved
material and compacted to a density not less than the density of the surrounding ground.
(c) Ground Surface Level after Clearing and Grubbing

All holes, ruts or other surface deformation remaining after clearing and grubbing should be backfilled
and compacted as directed by the Engineer to prevent the ponding of water. The cleared areas may
also require blading to improve drainage wherever possible.

(d) Conservation of Topsoil

Where topsoil exists within the limits of the area to be cleared and/or grubbed, the Engineer shall
designate areas for removal of the topsoil together with any grass and other suitable vegetation. If not
used immediately, the topsoil shall be transported and deposited in stockpiles for later use.
Measurement and payment for this activity shall be covered under item 96.01 of Clause 9608.
(e) Conservation of Vegetation

Where provided for in the Contract, certain designated plants encountered in the road reserve and
borrow areas shall be carefully protected by the Contractor.
2103 Execution of Work
(a) Areas to be Cleared and/or Grubbed

The portions of the road reserve that fall within the limits of the road prism as well as certain borrow
areas may require to be cleared and/or grubbed. The Engineer shall designate the areas to be cleared
and such areas shall not necessarily be limited to those mentioned herein.
The Contractor shall note that in order to avoid re-clearing, the clearing and/or grubbing may have to
be done immediately before subsequent construction activities.
The Contractor shall control the clearing and/or grubbing activities to ensure that the portion of the
road reserve that falls outside the limit of the road prism, or such areas as the Engineer shall
designate, shall not be cleared and/or grubbed. The areas to be cleared shall be the area on each side
of the road width, plus 1 m and 0.5 m in rural and town sections respectively beyond the catch-point in
cut and fill.
The Contractor shall take the necessary precautions to prevent damage to structures and other private
or public property. In addition, the Contractor shall not clear or grub any other areas, or shall not
dispose of any material obtained from clearing and/or grubbing without the approval of the Engineer.
No payment shall be made for any areas cleared and grubbed for temporary works at the Contractor’s
own initiative.
(b) Trees
Individual trees, designated in writing by the Engineer, shall be left standing and undamaged. A
penalty equal to the amount specified in the Particular Specifications shall be imposed for every such
tree, which is unnecessarily removed or damaged.
If necessary, trees shall be cut in sections from the top downwards. The branches of trees to be left
standing shall be trimmed so as not to intrude into the space for up to 7m in height above the roadway.
(c) Disposal of Material

Material obtained from clearing and/or grubbing shall be disposed of, as indicated by the Engineer, in
borrow pits or other suitable places and covered with soil or gravel. The burning of combustible
material will normally be permitted but may only be carried out with the prior written approval of the
Engineer. Care must be taken to observe any regulations related to air pollution.
All tree trunks and branches in excess of 150mm diameter shall be cleaned of secondary branches;
sawn into suitable lengths; and stacked at sites indicated by the Engineer. Such timber shall not be
used by the Contractor for any purpose and shall remain the property of the Employer unless
otherwise agreed with the Engineer.

Fencing wire shall be neatly wound into reels and all such wire, together with all fence posts and other
usable material shall be stacked at sites indicated by the Engineer.

The tendered rate for the specific measurement and payment item shall include the general
requirements of Series 0000.
Item 21.01 Clearing and grubbing .......................................................................... hectare (ha)

The unit of measurement for clearing and grubbing is the hectare (ha). The quantity shall be taken as
the area in hectares (to the nearest 0.1ha) designated by the Engineer and cleared and grubbed in
accordance with these Specifications. The measurement area for clearing and grubbing shall be the
plan area of the permanent Works. No deductions shall be made for buildings or structures and
existing carriageways shall not be measured.
Payment for fences which are removed, sorted, coiled and stored shall be made under Division 9800
of these specifications.
The tendered rate shall include full compensation for all work necessary for the clearing of the surface;
the removal and grubbing of vegetation, bushes, trees, tree stumps and roots, including any blasting
(not including those large trees and stumps covered in item 2102); cutting of branches; backfilling and
compaction of all holes and cavities; demolition, breaking up and disposal of walls and superficial
structures to existing ground level (except as otherwise stated in the Contract); making good to
severed ends of existing fences and walls; protection from damage of all vegetation and objects
designated to remain; and the removal, transporting and disposal of non-reusable material all as
specified in this Division.
Clearing and grubbing of borrow areas shall not be measured for payment. No clearing and grubbing
shall be measured for payment for roadworks or work on structures where cutting or excavation is
indicated in the Drawings and is prescribed to be spoiled by the Engineer.
The rate shall include disposal of all material and no separate payment will be made for this item.
Item 21.02 Grubbing and removal of large trees and tree stumps
a) Girth exceeding 1m up to and including 2m ........................................................... number (No)
b) Girth exceeding 2m up to and including 3m ........................................................... number (No)
c) Girth exceeding 3m up to and including 4m ........................................................... number (No)
The measurement for grubbing and removal of large trees and stumps (>1m girth) shall be the number
of trees and stumps. The girth of trees or stumps shall be measured at the narrowest point of the tree
or stump in the first metre of its height above ground level. Trees and stumps with a girth exceeding
1m shall be measured individually and classified according to size in increments of 1m as indicated in
the sub-clause item.
The tendered rate shall include felling of trees, grubbing and removal of stumps and roots; backfilling
and compacting stump and root holes with suitable material; protection from damage of all vegetation
and objects designated to remain; and the removal, transporting and disposal of non-reusable material
all as specified in this Division.
Item 21.03 Re-clearing of surfaces .......................................................................... hectare (ha)

The unit of measurement for re-clearing is the hectare (ha), but shall only be measured on the written
instruction of the Engineer. The quantity shall be taken as the plan area (to the nearest 0.1ha) re-
cleared in accordance with these Specifications.

The tendered rate for re-clearing shall be the same as for clearing and grubbing.
Re-clearing as a result of the Contractor’s failure to adequately protect the roadbed will not be
measured and/or considered.
Item 21.04 Removal and storage of selected vegetation

a) Cost of removal, storage, protection and replanting in a protected and fenced-off area of selected
vegetation...........................................................................................................provisional sum
b) Charge on provisional sum ............................................................................... percentage (%)
This item provides for a provisional sum for the removal, storage, protection and replanting of
vegetation approved by the Engineer as part of the clearing and grubbing work.
The removal, stockpiling and reuse of topsoil along with the replacement and replantation of trees are
covered under pay items 96.01 and 96.02 of Clause 9608.

Division 2200: Demolition, Removal, Disposal, Storage or Cleaning

of Existing Structures and Installations
2201 Scope
This Division covers the demolition, disconnection, removal or part removal, disposal and/or storage of
buildings, bridges, drainage structures, retaining walls, wells, buildings, service ducts, foundations,
fencing, walls, kerbs, old pavements, abandoned pipelines, disused public utilities and any other
obstructions which are not designated or permitted to remain; except for the obstructions to be
removed and disposed of under other items in the Contract.
This Division also covers the cleaning of existing drainage structures designated to remain as part of
the Works and includes cleaning, removal and disposal of materials related to the existing structure.
2202 Demolition of Structures

Existing structures and installations shall be carefully demolished as described in the Contract or as
instructed by the Engineer. The existing structures and installations shall be removed in such a way as
to leave no obstructions to the new Works. Those structures and installations which are to be partially
demolished, shall be shored, braced and supported in such a manner that the integrity of the structure
shall be maintained. All supports shall be kept outside the RoW.
The Contractor shall carefully remove and store materials salvaged from demolished structures and
installations. Unless otherwise stated in the Contract, such materials shall become the property of the
Owner. This material shall be carefully transported and stored in an acceptable manner upon the
adjacent property of the Owner, or at a location to be identified by the Engineer.
Whenever materials are stored within the RoW, the Contractor shall be responsible for its care and
preservation until its authorised removal. The Contractor shall satisfactorily dispose of all material
designated by the Engineer as having no salvage value in accordance with the requirements of
Division 1600.
Unless otherwise directed by the Engineer, any voids below ground level in existing structures or
installations shall be filled and compacted with natural sand or crushed fine aggregate to a density
approved by the Engineer. Structures such as latrine pits and septic tanks shall be cleaned and
disinfected and the contents disposed of in accordance with the requirements of Division 1600 before
filling and compacting with approved material, as instructed by the Engineer.
2203 Demolition of Existing Road Pavements

Existing road pavements shall be demolished by excavation, scarifying or milling using appropriate
equipment approved by the Engineer. Materials resulting from the removal of the existing road
pavement shall be disposed of, or stored as instructed by the Engineer.
2204 Cleaning of Existing Drainage Structures

The cleaning of existing drainage structures that are designated to remain as part of the Contract shall
be undertaken as directed by the Engineer. The work involves the cleaning of open drains and other
open structures, or the cleaning of piped or box-type drainage structures and their inlets and outlets.
All materials arising from such operations shall be disposed of as instructed by the Engineer.

2205 Construction Requirements for Existing Public Utilities
(a) Disconnections
Prior to the commencement of the Works, the Contractor shall be responsible for locating and
identifying all services. The Contractor shall contact all service authorities and arrange for the
disconnection of all disused public utilities including electricity, telephone, water, sewers and any other
service facilities encountered, to the satisfaction of the Engineer. All correspondence between the
Contractor and service authorities shall be copied to the Engineer.
(b) Protection of Existing Public Utilities

Existing public utilities, which are to remain in place, such as sewers, drains, water pipes, conduits and
poles, are to be carefully protected from damage and are not to be displaced. Any utilities damaged
through the negligence of the Contractor shall be replaced at the Contractor’s cost.
The Contractor shall also comply with the requirements of Clause 1207.
(c) Relocation of Existing Public Utilities

The Employer shall arrange with the appropriate authorities for the necessary relocation of any public
utilities, which would otherwise obstruct the Works.
The Contractor shall also comply with the requirements of Clause 1207.

Item 22.01 Clearing and grubbing at inlets and outlets of existing hydraulic structures
......................................................................................................... square metre (m²)
The unit of measurement for clearing and grubbing at inlets and outlets of existing hydraulic structures
2
is the square metre (m ) measured within the limits of the areas designated by the Engineer, which are
cleared and grubbed in accordance with these Specifications.
Item 22.02 Cleaning out of existing hydraulic structures (pipes and slab/box culverts)
a) Pipes with an internal diameter up to and including 750mm .............................. linear metre (m)
b) Pipes with an internal diameter exceeding 750mm ............................................. linear metre (m)
c) Slab or Box culverts up to and including 1.5m vertical dimension...................... linear metre (m)
d) Slab or Box culverts exceeding 1.5m vertical dimension ................................... linear metre (m)
The unit of measurement shall be the linear metre (m) of material removed from existing hydraulic
structures, where instructed by the Engineer so that the structures are cleaned as specified.
Payment under this item will normally only be made once, during the duration of the Contract.
Item 22.03 Take up or down and set aside for reuse; or remove to store off Site, the
following:
3
a) Blockwork and stonework .................................................................................. cubic metre (m )
2
b) Paved areas and the like, brickwork ............................................................... square metre (m )

c) Kerbs, channels, edgings, combined drainage and kerb blocks, fencing, safety fences and the
like, copings, string courses and the like ........................................................... linear metre (m)
d) Cable .................................................................................................................. linear metre (m)
e) Road lighting columns, brackets and wall mountings, traffic signs, reflecting road studs, gates,
stiles, street furniture, communications cabinets, posts, brackets, signal indicators, shelves,
racking, frames, electronic units and the like ......................................................... number (No)
f) Chamber covers and frames, gully gratings and frames and the like ..................... number (No)
g) Individual blocks, features or stones ...................................................................... number (No)
The measurement for take up or down and set aside for reuse; or remove to store off Site for
blockwork and stonework shall be the cubic metre.
For paved areas and the like; and brickwork, the measurement shall be the square metre.
For kerbs; channels; edgings; combined drainage and kerb blocks; fencing; safety fences and the like;
copings; string courses and the like; and cable, the measurement shall be the linear metre.
The measurement for take up or down and set aside for reuse or remove to store off Site for road
lighting columns; brackets and wall mountings; traffic signs; reflecting road studs; gates; stiles; street
furniture and the like; communications cabinets, posts, brackets, signal indicators, shelves, racking,
frames, electronic units and the like; chamber covers and frames, gully, gratings and frames and the
like; individual blocks, features or stones shall be the numbers stated in the Contract.
The tendered rate shall include the following specific requirements:
 Demolition of the buildings or structures, including blasting if necessary down to existing

ground level;
 Disconnecting and sealing services;
 Excavation in normal ground including loading into transport, upholding the sides and keeping
the earthworks free of water;
 Loosening or breaking up by blasting or other means sewer or drain of whatever type of
construction together with any bed and haunch or surround;
 Cutting through reinforcement;
 Trimming the bottom and sides of excavation and clearing away loose material;
 Overbreak and making good;
 Backfilling with suitable material from any source and compaction;
 Disposal of surplus material;
 Backfilling manholes etc. with suitable material from any source and compaction.
Both dry and grouted stone pitching can be considered under item 22.03 (b).
Item 22.04 Cleaning of existing open drainage structures ............................ linear metre (m)
The unit measurement for cleaning of existing open drainage structures shall be the linear metre
measured within the limits of the open drainage structure as designated by the Engineer.
The tendered rate shall include precautions to avoid damage to property, structures, sewers, drains
and services; excavation of material; loading, multi-handling, transport and disposal of material; and
protection and relocation of existing public utilities.

Item 22.05 Removal of existing road pavements ........................................... cubic metre (m³)
The measurement for the removal of an existing road pavement shall be the cubic metre of material
measured in its original position and calculated by multiplying the plan area of the existing carriageway
by the depth to be removed as instructed by the Engineer.
The tendered rate shall include loosening or breaking up of material by any means; cutting through
reinforcement; loading into transport; protection of the subgrade; replacing material deemed to be
unsuitable by the Engineer; selection, separation, multiple handling and transportation of material;
over-break and making good; forming and trimming side slopes, benching, berms, trimming the bottom
and sides of excavations and clearing away loose material; taking precautions to avoid damage to
property; and haulage disposal or temporary stockpiling, including the provision of sites for stockpiles.
Item 22.06 Removal of existing concrete and masonry structures

a) Plain concrete .................................................................................................... cubic metre (m³)
b) Reinforced concrete ........................................................................................... cubic metre (m³)
c) Masonry Structures - mortared ........................................................................... cubic metre (m³)
d) Masonry Structures - dry..................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of existing concrete or masonry structures removed.
Payment shall distinguish between plain and reinforced concrete and mortared and dry masonry.
The tendered rate shall include loosening or breaking up of material by any means; cutting through
reinforcement; precautions to avoid damage to property, structures, sewers, drains and services;
loading, multi-handling, transport and disposal of material; and protection and relocation of existing
public utilities.

Series 3000: Drainage Structures
TABLE OF CONTENTS
DIVISION 3100: OPEN DRAINS, CASCADES, BANKS, DYKES AND SUB-SOIL DRAINS................................ 171
3101 Scope ........................................................................................................................................ 171
3102 Dimensions ............................................................................................................................... 171
3103 Open Drains (trenches) and Cascades .................................................................................... 171
3104 Furrow Drains ........................................................................................................................... 171
3105 Mitre Drains .............................................................................................................................. 171
(a) Mitre Drain Type 1 ........................................................................................................................ 171
(b) Mitre Drain Type 2 ........................................................................................................................ 172
3106 Banks and Dykes ...................................................................................................................... 172
3107 Subsoil (sub-surface) Drainage ................................................................................................ 172
(a) Materials ....................................................................................................................................... 172
(i) Pipes ......................................................................................................................................................... 172
(ii) Natural Filter Materials for Subsoil Drains .............................................................................................. 172
(iii) Synthetic-fibre filter fabric ....................................................................................................................... 173
(iv) Composite in-plane draining fabric .......................................................................................................... 174
(v) Concrete .................................................................................................................................................... 174
(vi) Galvanized woven wire mesh ................................................................................................................... 174
(b) Construction of subsoil drainage systems ..................................................................................... 174
(i) With natural permeable material ............................................................................................................... 174
(ii) With polyethylene lining to trenches for subsoil drainage systems .......................................................... 174
(iii) With synthetic-fibre filter fabric ............................................................................................................... 175
(iv) With composite in-plane drainage fabric .................................................................................................. 175
(c) Test flushing .................................................................................................................................. 175
3108 Manholes, Outlet Structures and Cleaning Eyes ...................................................................... 175
3109 Classification of Materials ......................................................................................................... 175
DIVISION 3200: CULVERTS AND APPURTENANT STRUCTURES ................................................................ 180
3201 Scope ........................................................................................................................................ 180
3202 Dimensions ............................................................................................................................... 180
3203 Types of Culverts ...................................................................................................................... 180
3204 Materials ................................................................................................................................... 180

(a) Concrete Pipes ............................................................................................................................... 180
(b) Corrugated Metal Pipes .................................................................................................................180
(c) PVC Drain Pipes ........................................................................................................................... 181
(d) Corrugated Polyethylene Drainage Tubing Drain Pipes ................................................................ 181
(e) Corrugated Polyethylene Drain Pipes ........................................................................................... 181
3205 Construction Methods ............................................................................................................... 181
3206 Excavation by Trench Method .................................................................................................. 181
(a) Depth of Excavation ...................................................................................................................... 181
(i) Concrete Pipe Culverts.............................................................................................................................. 182
(ii) Metal Culverts ........................................................................................................................................... 182
(b) Width of excavation ...................................................................................................................... 182
3207 Unsuitable Foundation Conditions ............................................................................................ 182
3208 Excavation for Embankment Conditions ................................................................................... 182
3209 Disposal of Excavated Material ................................................................................................ 183
3210 Bedding and Laying of Prefabricated or Cast in-situ Pipe Culverts and Drains ....................... 183
(a) Concrete Pipe Culverts and Drains................................................................................................ 183
(i) Class A Bedding ........................................................................................................................................ 183
(ii) Class B and Class C Beddings .................................................................................................................. 183
(iii) Class D Bedding ....................................................................................................................................... 183
(iv) Rock Foundation ....................................................................................................................................... 183
(v) Concrete Casing ........................................................................................................................................ 184
(b) Metal Culverts ............................................................................................................................... 184
(c) Extension of Existing Culverts ......................................................................................................184
(d) Construction of Culverts in Half-Widths in Existing Roads ......................................................... 184
(e) General ..........................................................................................................................................184
3211 Backfilling of Prefabricated Culverts and Storm-water Drains .................................................. 185
3212 Inlet and Outlet Structures ........................................................................................................ 186
(a) Excavation and Backfilling ...........................................................................................................186
(b) Concrete Work ............................................................................................................................... 186
3213 Removal of Existing Work ......................................................................................................... 186
3214 Joining New Work to Old .......................................................................................................... 186
3215 Service Ducts ............................................................................................................................ 187
3216 Culverts on Steep Gradients ..................................................................................................... 187
3217 Stormwater Ducts and other Closed Conduits.......................................................................... 188

3218 Manholes, Outlet Structures and Cleaning Eyes ...................................................................... 188
DIVISION 3300: KERBING, CHANNELLING, OPEN CHUTES, DOWNPIPES, AND LINING OF OPEN DRAINS .... 195
3301 Scope ........................................................................................................................................ 195
3302 Kerbing and Channelling .......................................................................................................... 195
(a) Dimensions ................................................................................................................................... 195
(b) Material Requirements for Kerbing and Channelling ................................................................... 195
(i) General ..................................................................................................................................................... 195
(ii) Natural Stone ............................................................................................................................................ 195
(iii) Concrete for Kerbing and Channelling ..................................................................................................... 195
(iv) Mortar for Bedding of Kerbing and Channelling ...................................................................................... 196
(v) Water for Kerbing and Channelling .......................................................................................................... 196
(vi) Asphalt Kerbing ........................................................................................................................................ 196
(c) Construction Requirements for Kerbing and Channelling ............................................................ 196
(i) General ..................................................................................................................................................... 196
(ii) Equipment ................................................................................................................................................. 196
(iii) Excavation for Foundations ...................................................................................................................... 196
(iv) Laying Natural Stone or Pre-cast Concrete Kerbing and Channelling ..................................................... 196
(d) Cast In-Situ Concrete Kerbs and Channels ................................................................................... 197
(e) Cast In-Situ Concrete Kerbs and Channels (Sliding Forms) ......................................................... 197
(f) Cast In-Situ Asphalt Kerbs ............................................................................................................ 198
(g) Construction Sequence .................................................................................................................. 199
(i) Where Kerbs and Channels are Constructed before the Base ................................................................... 199
(ii) Where Kerbs and Channels are Constructed after the Base ...................................................................... 199
(iii) Where Kerbs and Channels are Constructed after the Asphalt Base and/or Asphalt Surfacing ................ 199
3303 Open Chutes and Linings for Open Drains .............................................................................. 199
(a) Material Requirements for Open Chutes and Concrete Linings for Open Drains ......................... 199
(i) Concrete .................................................................................................................................................... 199
(ii) Reinforcement .......................................................................................................................................... 199
(iii) Masonry and Stone Pitching ..................................................................................................................... 199
(iv) Concrete Drain Covers ............................................................................................................................. 199
(b) Construction Requirements for Open Chutes and Linings for Open Drains ................................. 200
(i) Excavation and Preparation of Bedding ................................................................................................... 200
(ii) Concrete, Stone-Pitching and Masonry Linings ....................................................................................... 200
(iii) Chutes ....................................................................................................................................................... 200

(iv) Cast In-Situ Chutes on Cut Slopes ............................................................................................................ 200
(v) Concrete-Lined Open Drains .................................................................................................................... 200
3304 Inlet and Outlet Structures and Transition Sections ................................................................. 201
3305 Construction Tolerances and Surface Finish ............................................................................ 201
(a) Concrete Kerbing and Channelling ............................................................................................... 201
(i) Horizontal Alignment ................................................................................................................................ 201
(ii) Vertical Alignment and Level ................................................................................................................... 201
(iii) Trueness of Exposed Surfaces................................................................................................................... 201
(iv) Cross-Sectional Dimensions ..................................................................................................................... 201
(b) Concrete-Lined Channels ..............................................................................................................201
(i) Horizontal Alignment ................................................................................................................................ 201
(ii) Vertical Alignment .................................................................................................................................... 201
(iii) Trueness of Exposed Surfaces................................................................................................................... 202
(iv) Cross-Sectional Dimensions ..................................................................................................................... 202
(c) Surface Finish................................................................................................................................ 202
DIVISION 3400: STONE PITCHING, M ASONRY, PRECAST CONCRETE BLOCK AND RIPRAP......................... 207
3401 Scope ........................................................................................................................................ 207
3402 Materials.................................................................................................................................... 207
(a) Stone..............................................................................................................................................207
(i) Pitching and Masonry ............................................................................................................................... 207
(ii) Riprap........................................................................................................................................................ 207
(b) Cement ..........................................................................................................................................207
(c) Sand ...............................................................................................................................................207
(i) Sand for Cement Mortar ........................................................................................................................... 207
(ii) Sand for Bedding ...................................................................................................................................... 207
(iii) Sand for Joints........................................................................................................................................... 207
(d) Precast Concrete Blocks ................................................................................................................208
(e) Concrete ........................................................................................................................................208
(f) Wire ...............................................................................................................................................209
(g) Permeable Material for Filter Layers ............................................................................................ 209
(h) Synthetic Fibre Filter Fabric (Geotextiles) ....................................................................................209
3403 Construction Requirements for Stone Pitching ......................................................................... 209
(a) Dry Stone Pitching ........................................................................................................................ 209

(i) Method 1 ................................................................................................................................................... 209
(ii) Method 2 ................................................................................................................................................... 209
(iii) Finished Surface Tolerances ..................................................................................................................... 209
(b) Grouted Stone Pitching ................................................................................................................. 209
(c) Wired and Grouted Stone Pitching ................................................................................................ 210
(d) Grouted Stone Pitching on a Concrete Bed ................................................................................... 210
3404 Riprap ....................................................................................................................................... 210
(a) General .......................................................................................................................................... 210
(b) Filter Bed ...................................................................................................................................... 211
(c) Packed Riprap ............................................................................................................................... 211
(d) Dumped Riprap ............................................................................................................................. 211
3405 Stone Masonry Walls .................................................................................................................211
(a) General .......................................................................................................................................... 211
(b) Dry Stone Masonry Walls ............................................................................................................. 211
(c) Cement Mortared Stone Masonry Walls ....................................................................................... 212
3406 Concrete Block Pitching ........................................................................................................... 212
(a) General .......................................................................................................................................... 212
(b) Interlocking Type Concrete Blocks ............................................................................................... 212
(c) Precast Concrete Blocks for Footway Pavements ......................................................................... 213
3407 Cast In-Situ Concrete Pitching ................................................................................................. 213

List of Tables
Table 3107/1: Range of Grading of Filter Material ............................................................................... 173
Table 3107/2: Natural permeable materials: sand ............................................................................... 173
Table 3107/3: Physical Requirements for Subsurface Drainage Geotextile ........................................ 173
Table 3402/1: Gradation Requirements for Riprap .............................................................................. 208
Table 3402/2: Sand for Bedding .......................................................................................................... 208

Division 3100: Open Drains, Cascades, Banks, Dykes and Sub-Soil

Drains
3101 Scope
This Division covers all work in connection with the excavation and construction of unlined open drains
(hereinafter in this Division referred to as open drains) and cascades, subsoil (sub-surface) drainage,
banks and dykes at the respective locations and to the sizes, shapes, grades and dimensions as
shown on the Drawings or as directed by the Engineer.
Concrete-lined open drains are covered in Division 3300.
3102 Dimensions
Excavations for open drains and trenches for piped and subsoil drains, shall be true to line, gradient
and cross section as described in the Contract or as otherwise directed by the Engineer.
The alignment of pipes for piped and subsoil drains shall be true to line, gradient and cross section as
described in the Contract or as otherwise directed by the Engineer.
3103 Open Drains (trenches) and Cascades

Open drain and cascade excavations shall include the re-excavation or excavation of open drains and
cascades inside or outside the road reserve (including channels to direct the course of streams) all as
shown on the Drawings or as directed by the Engineer. Open drain and cascade excavations shall
include all excavations required to construct channels with side slopes and inverts as defined on the
Drawings.
Open drains and cascades shall be constructed true to line, grade, and cross section and shall be so
maintained for the duration of the Contract. Care shall be exercised to avoid excavation below the
required grade for the open drain and cascade. Any excavation carried out below the required grade
shall be backfilled with suitable material and compacted to at least 97% of modified AASHTO density,
at the cost of the Contractor.
Material resulting from the excavation of open drains shall be used in the construction of fills, banks
and dykes; or for other purposes; or disposed of to spoil; depending on the classification and suitability
of such material.
3104 Furrow Drains

Furrow drains shall be formed by ploughing a continuous furrow along the line indicated in the
Contract or as directed by the Engineer. Methods other than ploughing may be used if acceptable to
the Engineer. The excavated material shall be placed on the downside of the open drain and shall be
compacted to at least 90% of modified AASHTO density in layers not exceeding 150mm in thickness.
The bottom of the finished open drain shall be at least 500mm below the crest of the downhill material.
Flow lines shall provide satisfactory shape to provide drainage to the outlet without causing scour,
sedimentation or damage to adjacent property.
3105 Mitre Drains
(a) Mitre Drain Type 1

Mitre drain Type 1 shall be constructed of suitable material, to be approved by the Engineer, and shall
be placed in such a way that the water will flow on the natural ground and against the mitre bank. The

mitre bank shall be compacted to 90% of modified AASHTO density in layers not exceeding 150mm in
thickness, unless the Engineer has approved thicker layers.
(b) Mitre Drain Type 2

Mitre drain Type 2 shall be constructed from rip-rap in accordance with Division 3400. The interstices
shall be filled with a suitable cohesive soil, to be approved by the Engineer.
3106 Banks and Dykes

Mitre banks, catch-water banks and dykes shall be constructed of approved soil or gravel obtained
from open drain excavation or, if no suitable material can be obtained from the source, from suitable
alternative sources; and shall be placed in such a way that the water will flow on the natural ground
and against the bank.
The banks and dykes shall be compacted to 90% of modified AASHTO density in layers not exceeding
150mm in thickness, unless thicker layers have been approved by the Engineer.
If so preferred by the Contractor and approved by the Engineer, mitre banks may also be constructed
of hand-packed stone, provided that the interstices are filled with an approved cohesive soil.
3107 Subsoil (sub-surface) Drainage
(a) Materials
(i) Pipes
Pipes for subsoil drainage shall have the specified internal diameter, which shall be not less than
100mm, and shall be one of the following types:
 Perforated or slotted PVC pipes complying with AASHTO M304.

 Perforated polyethylene pipes complying with the requirements of AASHTO M252.
The size of perforations in perforated pipes shall, in all cases, be 8mm in diameter and the number of
perforations per metre shall be not less than 26 for 100mm pipes and 52 for 150mm pipes.
Perforations shall be spaced in two rows for 100 mm pipes and as shown on the Drawings for 150mm
pipes.
Slotted pipes shall have a slot width of 8mm  1.5mm. The arrangement of slots shall be subject to the
Engineer’s approval, but the total slot area shall be not less than that specified for perforations.
Pipes without slots or perforations required for conveying ground water from the subsoil drainage to
the point of discharge, shall be uPVC or polyethylene pipes of the types specified above, or concrete
pipes complying with the requirements of AASHTO M86M or M175M.
(ii) Natural Filter Materials for Subsoil Drains

Natural permeable filter materials for subsoil drainage shall consist of sand and/or crushed stone or
natural gravel of suitable grading. The grading shall comply with the requirements of Table 3107/1.
Gravel filter material shall consist of Type A, Type B or Type C filter material within the grading limits
shown in Table 3107/1. The filter material shall be clean, hard, durable crushed rock or gravel and free
from organic impurities. The Aggregate Crushing Value (ACV) of the material shall not exceed 25. The
material passing the 425 m sieve shall be non-plastic when tested in accordance with ASTM D-4318.

Table 3107/1: Range of Grading of Filter Material
Mass Passing (%)

Sieve Size
Type A Type B Type C
63 mm - 100 100
37.5 mm 100 85 - 100 0
20 mm 45 - 100 0 - 20 -
10 mm 45 - 100 0-5 -
3.35 mm 25 - 80 - -
600 m 8 - 45 - -
150 m 0 - 10 - -
75 m 0-5 - -
Sand shall be clean and hard, and obtained from an approved borrow pit. The nominal maximum
particle size for the various grades shall be as shown in Table 3107/2.
Table 3107/2: Natural permeable materials: sand
Nominal maximum
Grade
Particle size (mm)
Coarse 4.75
Medium 2.0
Fine 0.2
Crushed stone shall comply with the requirements given in Series 5000. The Aggregate shall be
evenly graded. The ACV of the stone shall not exceed 25.
The Engineer shall indicate the grades of sand and crushed stone to be used in each case to comply
with the requirements.
In the case of any sand and/or crushed stone, not more than 5% of the material shall pass through the
75m sieve.
(iii) Synthetic-fibre filter fabric

Synthetic-fibre filter fabric shall comply with the requirements in Table 3107/3.
Table 3107/3: Physical Requirements for Subsurface Drainage Geotextile

(1)
Test Specifications
Property Method Units
Type I-A Type I-B Type I-C Type I-D Type I-E Type I-F
ASTM
Grab
D 4632 N 1100/700 1100/700 1100/700 800/500 800/500 800/500
Strength
Sewn Seam
D 4632 N 990/630 990/630 990/630 720/450 720/450 720/450
Strength
Tear (3) (3) (3)
D 4533 N 400 /250 400 /250 400 /250 300/175 300/175 300/175
Strength
Puncture
D 4833 N 400/250 400/250 400/250 300/175 300/175 300/175
Strength
Burst
D 3786 kPa 2750/1350 2750/1350 2750/1350 2100/650 2100/950 2100/950
Strength
-1
Permittivity D 4491 s 0.5 0.2 0.1 0.5 0.2 0.1
Apparent
(2) (2) (2) (2) (2) (2)
Opening D 4751 mm 0.45 0.25 0.22 0.45 0.25 0.22
Size
Ultraviolet
D 4355 % 50% after 500 hours of exposure
Stability
(1)
The first values in a column apply to geotextiles that break at <50 per cent elongation (ASTM D 4632). The second values in a
column apply to geotextiles that break at 50 elongation (ASTM D 4632).
(2)
Maximum average roll value.
(3)
The minimum average roll tear strength for woven monofilament geotextile is 245 N.

(iv) Composite in-plane draining fabric

The make and class of fabric shown on the Drawings or approved by the Engineer shall be used.
(v) Concrete
All concrete work shall be carried out in accordance with the requirements of Series 8000 and with the
details shown on the Drawings.
(vi) Galvanized woven wire mesh

Galvanized woven wire mesh manufactured from 3.5mm diameter wire, 250mm x 250mm in area, with
a 12mm x 12mm maximum mesh size, shall be built into the outlets of subsoil drainage systems in
accordance with the details shown on the Drawings.
(b) Construction of subsoil drainage systems
(i) With natural permeable material

Trenches for subsoil drainage systems shall be excavated to the dimensions and gradients shown on
the Drawings or as directed by the Engineer.
A layer of natural permeable material of the grade and thickness shown on the Drawings shall be
placed at the bottom of the trench and be lightly tamped and finished to the required gradient.
Pipes of the type and size required shall be firmly bedded on the natural permeable material, true to
level and grade, and be coupled in accordance with manufacturer’s requirements. Thereafter, the
trench shall be backfilled with natural permeable material to such height above the pipes as shown on
the Drawings or as directed by the Engineer. The natural permeable material shall be lightly
compacted and trimmed to the required level. Further layers of finer natural permeable materials shall
then be placed, lightly compacted and finished to an even surface. The remainder of the trench, if any,
shall be backfilled with approved impermeable material, in layers not exceeding 100mm, and
compacted to at least the same density as the surrounding material. The trench shall be specially
protected against the ingress of water until the impermeable layer has been completed.
Natural permeable material shall be placed in layers not exceeding 300mm in thickness and be lightly
compacted. The total thickness of each type of natural permeable material shall be carefully
controlled, and when the thinner layers are placed suitable spacers shall be used. When successive
layers are placed, the lower layer shall not be disturbed. Care shall be taken to prevent contamination
of the natural permeable material during construction and all natural permeable material contaminated
by soil or silt shall be removed and replaced by the Contractor at his own cost.
Perforated and slotted pipes shall be joined by means of proprietary couplings. Perforated pipes shall
be laid with perforations at the top or bottom as prescribed.
The higher end of each subsoil drainage pipe shall be sealed off with a loose concrete cap of Class C
20/20 concrete, as shown on the Drawings. At the lower end the pipe shall be built into a concrete
head wall providing a positive outlet; or it shall be connected to storm water pipes or culverts. The
complete system together with headwalls shall be constructed in one process starting at the lower
headwall.
Any section of a subsoil drainage system constructed of pipes without perforations or slots shall be
backfilled with impermeable backfill material as described herein. Where suitable, the excavated
material shall be used for backfilling.
(ii) With polyethylene lining to trenches for subsoil drainage systems

Where shown on the Drawings or as directed by the Engineer, trenches for subsoil drainage systems
shall be lined with approved polyethylene sheeting 0.15mm thick. The polyethylene sheet shall cover
the bottom of the trench and shall extend upwards on both sides for as far as may be directed by the

Engineer in each particular case, in order to form a waterproof channel. At joints the polyethylene
sheeting shall be heat-welded together or lapped by a minimum of 200mm.
When backfilling the trench with natural permeable material, care shall be taken not to displace or
damage the polyethylene lining in any way. The use of plastics other than polyethylene may be
considered provided that the material is of equal quality and is approved by the Engineer.
(iii) With synthetic-fibre filter fabric

Where specified, synthetic-fibre filter fabric shall be used for lining subsoil drainage systems. It shall
be procured, furnished and installed as specified and shown on the Drawings. The lining shall not be
displaced or damaged in any way when the trench is being filled with natural permeable material. The
filter fabric shall be lapped both longitudinally and transversely by at least 300mm or in accordance
with the manufacturer’s recommendations. The transverse lap shall be positioned on top of the box
forming the drain and shall be stitched together with plastic/galvanized wire or strong synthetic thread
at one (1) metre intervals. The longitudinal lap shall be in the direction of flow.
Filter fabric shall be stored under suitable cover and shall not be exposed to direct sunlight for
prolonged periods and shall be protected from mechanical damage during installation and
construction.
(iv) With composite in-plane drainage fabric

Composite in-plane drainage systems shall be constructed in accordance with the details shown on
the Drawings. The elements of the system shall be assembled above ground in manageable lengths,
and all exposed surfaces shall be sealed with an approved geofibre seal. The trench sides shall be
vertical, and the composite in-plane system shall be installed against the side through which the
subsoil flow is expected. The trench shall then be backfilled with sand, which shall be saturated with
water after placement up to the prescribed level. The upper part of the trench shall be backfilled with
impermeable material, which shall be compacted to the density of the surrounding material, in layers
not exceeding 100mm in thickness.
(c) Test flushing

Final acceptance of longitudinal subsoil drains will be subject to satisfactory test flushing after
completion and installation of the rodding eye inlets. Flushing tests shall be carried out in the presence
of the Engineer by flushing the pipe and metering outflow to ensure the drain is clear of blockage.
Should blockages be apparent the Contractor shall locate and clear the obstruction and repeat the
test.
3108 Manholes, Outlet Structures and Cleaning Eyes

Manholes, outlet structures and cleaning eyes for subsoil drainage systems shall be constructed in
accordance with the details shown on the Drawings or in locations as instructed by the Engineer.
3109 Classification of Materials

All excavated materials for open drains and subsoil drainage systems shall be classified as specified
in Clause 4204.


Item 31.01 Excavation for Open Drains

a) Excavating soft material situated within the following depth ranges below the surface level:
3
(i) 0 to 1.5m ........................................................................................... cubic metre (m )
3
(ii) 1.5 to 3.0m ....................................................................................... cubic metre (m )
3
(iii) > 3.0m in increments of 1.5m .......................................................... cubic metre (m )
b) Extra-over sub-item 31.01(a) for excavation in hard material, irrespective of depth .................
........................................................................................................................ cubic metre (m³)
c) Mitre Drains
(i) Type 1 .............................................................................................. cubic metre (m3)
(ii) Type 2 .............................................................................................. cubic metre (m3)
d) Furrow Drains....................................................................................................... linear metre (m)
The unit of measurement shall be the cubic metre of material excavated in accordance with the
authorised dimensions measured in place before excavation for items 31.01 (a), (b) and (c).
Furrow drains in item (d) shall be paid for he linear metre of drain excavated.
Only excavations for drains as defined in Clause 3103, 3104 and 3105 shall be measured.
Irrespective of the total depth of the excavation, the quantity of material in each depth range shall be
measured and paid for separately.
The tendered rates shall include full compensation for the excavation of the material to the required
lines, levels and grades and the disposal of the material as approved by the Engineer.
For payment purposes a distinction shall be made between soft and hard material as defined in
Clause 3109.
3
Item 31.02 Clearing and shaping existing open drains ................................. cubic metre (m )
The tendered rate shall include full compensation for excavating the material, protecting the existing
drainage structures, trimming the floors and sides of the open drains and disposing of material as
prescribed.
Item 31.03 Excavation for subsoil drainage systems

3
(i) 0 to 1.5m ........................................................................................... cubic metre (m )
3
(ii) >1.5m ................................................................................................ cubic metre (m )
b) Extra-over sub item 31.03(a) for excavation in hard material irrespective of depth ...................
......................................................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated in accordance with the
authorised dimensions and measured in place before excavation. Irrespective of the total depth of
excavation, the quantity of the material in each depth range shall be measured and paid for separately.
The tendered rates shall include full compensation for the excavation of the material to the required
lines, levels and grades; all temporary shoring and strutting; and the disposal of the material as
directed. For payment purposes a distinction shall be made between soft and hard material, as defined
in clause 3109.

Where subsoil drainage systems are adjacent to drainage structures such as culverts, that part of the
excavation for subsoil drainage systems which can be made by widening the excavation for the
structure shall be measured and paid for under excavation for such structure, and not under
excavation for the subsoil drainage systems covered by this payment item.
Item 31.04 Impermeable backfilling to subsoil drainage systems ................ cubic metre (m³)
The unit of measurement shall be the cubic metre of completed backfill measured in place in the
subsoil drainage systems and calculated in accordance with the authorised dimensions.
The tendered rate shall include full compensation for procuring, furnishing, transporting, placing and
compacting the backfill.
Item 31.05 Banks and dykes ............................................................................ cubic metre (m³)

The unit of measurement shall be the cubic metre of material measured in place in the banks or dykes
and calculated in accordance with the authorised dimensions.
The tendered rate shall include full compensation for procuring, furnishing, transporting, placing,
watering, compacting, shaping and trimming the material in the banks and dykes.
Item 31.06 Natural permeable material in subsoil drainage systems (crushed stone)
a) Crushed stone obtained from approved sources on the site (state grade) ....... cubic metre (m³)
b) Crushed stone obtained from commercial sources (state grade) ..................... cubic metre (m³)
The unit of measurement shall be the cubic metre of crushed stone in place in the drains calculated in
accordance with the authorised dimensions. The volume occupied by the pipes shall be deducted
when calculating the volume of the permeable material.
The tendered rate shall include full compensation for procuring, furnishing and transporting approved
crushed stone from commercial suppliers to the site; and placing the materials as specified.
For payment purposes a distinction shall be made between the different grades of crushed stone.
Item 31.07 Natural permeable material in subsoil drainage systems (sand)

3
a) Sand obtained from approved sources on the site (state grade) ....................... cubic metre (m )
3
b) Sand from commercial sources (state grade) .................................................... cubic metre (m )
The unit of measurement shall be the cubic metre of sand in place in the drains calculated in
accordance with the authorised dimensions. The volume occupied by the pipes shall be deducted
when calculating the volume of the permeable material.
The tendered rate shall include full compensation for procuring, furnishing, transporting approved sand
from commercial suppliers to the site and placing the material as specified.
For payment purposes a distinction shall be made between the different grades of sand.
Item 31.08 Pipes in subsoil drainage systems

a) Pitch-fibre pipes and fittings complete with couplings (state size and whether or not perforated)
.......................................................................................................................... linear metre (m)
b) Unplasticised PVC pipes and fittings, normal duty, complete with couplings (state size and
whether or not perforated or slotted) ................................................................ linear metre (m)
c) High-density type polyethylene pressure pipes and fittings, complete with couplings (state size,
type and class and whether or not perforated) ................................................. linear metre (m)

d) Concrete pipes (state type and diameter) ......................................................... linear metre (m)
The unit of measurement for pipes shall be the linear metre of pipe measured in place along its centre
line, including the length of fittings.
The tendered rate shall include full compensation for procuring, furnishing, transporting, laying and
jointing the pipes and fittings as specified.
Item 31.09 Polyethylene sheeting, 0.15mm thick or similar approved material, for lining
subsoil drainage systems ............................................................. square metre (m²)
The unit of measurement shall be the square metre of polyethylene sheeting installed, and measured
nett from the specified dimensions.
The tendered rate shall include full compensation for procuring, supplying, transporting, cutting,
overlapping, jointing, placing and protecting the sheeting as specified; as well as for wastage.
Item 31.10 Synthetic-fibre filter fabric (describe type, grade, etc) .............. square metre (m²)
The unit of measurement shall be the square metre of filter fabric supplied and installed as specified.
The tendered rate shall include full compensation for furnishing, procuring, transporting, cutting,
overlapping, jointing, placing and protecting the filter fabric as specified; as well as for wastage.
Item 31.11 Composite in-plane drainage systems (state size, type, grade, etc) .....................
............................................................................................................ linear metre (m)
The unit of measurement shall be the linear metre of composite in-plane drainage system measured in
place along the centre line of the system.
The tendered rate shall include full compensation for procuring, furnishing, transporting, assembling,
installing and jointing the composite in-plane drainage system, including perforated or other types of
pipes, complete as specified.
Item 31.12 Concrete outlet structures, manhole boxes, junction boxes and cleaning eyes for
subsoil drainage systems
a) Outlet structures ....................................................................................................... number (No)
b) Manholes boxes ........................................................................................................ number (No)
c) Junction boxes .......................................................................................................... number (No)
d) Cleaning eyes ........................................................................................................... number (No)
The unit of measurement shall be the number of outlet structures, manhole boxes, junction boxes and
cleaning eyes for subsoil drainage systems constructed in accordance with the details on the
Drawings and the Engineer's instructions.
The tendered rates shall include full compensation for all excavations; backfilling; compacting to 90%
of modified AASHTO density; disposing of surplus excavated material; keeping the excavations safe;
dealing with any surface or subsurface water; procuring and furnishing all materials; providing,
erecting and removing formwork; mixing, transporting, placing and curing the concrete; and all labour
and construction plant required for constructing the concrete outlet structures, manhole boxes, junction
boxes and cleaning eyes; complete as specified.
Item 31.13 Concrete caps for subsoil drain pipes ................................................. number (No)
The unit of measurement shall be the number of caps supplied, and the tendered rate shall include full
compensation for supplying and installing the caps.
Item 31.14 Repairing or replacing existing drainage systems ....................... provisional sum
The provisional sum given for repairing or replacing existing drainage systems shall be expended in
terms of the General Conditions of Contract.
Item 31.15 Backfilling existing eroded side drains ......................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of approved granular material placed and
compacted to 93% of modified AASHTO density, measured in place after compaction, where
instructed by the Engineer.
The tendered rate shall include full compensation for trimming the side drains disposing of the
resulting material and procuring, furnishing, transporting, placing and compacting the granular
material.
Item 31.16 Test flushing of pipe subsoil drains ..................................................... number (No)
The unit of measurement shall be the number of tests satisfactorily completed on unblocked sections
of drain. No payment will be made for tests, which have to be repeated due to blocked pipes or faulty
workmanship.
The tendered rate shall include full compensation for the provision of a water tanker, water, equipment
and labour necessary to carry out the tests, complete as specified.
Item 31.17 Excavation for the clearing of existing drainage Systems:

a) Manholes and inlet and outlet structures ............................................................ cubic metre (m³)
b) Culvert barrels ................................................................................................... cubic metre (m³)
c) Concrete side drains .......................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated and removed, measured in
place before excavation.
The tendered rate shall include full compensation for excavating the material; protecting the existing
drainage structures; dealing with any surface or subsurface water; and disposing of the excavated
material including shaping and levelling-off piles of spoil material. The tendered rate shall also include
full compensation for transporting the excavated material.
Item 31.18 Cascades .......................................................................................... linear metre (m)

The unit of measurement shall be the linear metre of the cascade constructed as per the Drawings or
as directed by the Engineer, measured in place.
The tendered rate shall include excavation, haulage and reuse/disposal of materials; trimming side
slopes and inverts; levelling and compacting of bedding material; cement mortared masonry walling as
specified in sub-clause 3405(c); formwork as specified in Division 8200; steel reinforcement as
specified in Division 8300; and in-situ concrete as specified in Division 8400.

Division 3200: Culverts and Appurtenant Structures
3201 Scope
This Division covers the construction of in-situ and prefabricated drainage culverts for new and
extension works, together with inlet and outlet structures, and other appurtenant structures at the
locations and to the dimensions shown on the Drawings or as directed by the Engineer. No distinction
in payment shall be made between new construction and extension works.
All concrete works for culverts shall be in line with the requirements of Divisions 8200, 8300, 8400 and
81100 of Series 8000 and shall not be repeated as part of this Division.
The specifications for Structures (bridges) for river crossings (including foundation requirements), and
slab and box culverts (cast in-situ or prefabricated), are covered in Series 8000.
3202 Dimensions
Culverts shall be constructed to the dimensions and levels described in the Contract or as instructed
by the Engineer.
Excavations and alignments for culverts and appurtenant structures shall be true to line, gradient and
cross section as described in the Contract or as instructed by the Engineer.
3203 Types of Culverts

The following types of culverts are covered:
 Prefabricated concrete pipes of circular section, hereinafter called “concrete pipe culverts”.
 Prefabricated corrugated metal pipes and pipe arches, hereinafter called “metal culverts”.
These may be of steel or aluminium construction.
The specifications for other types of culverts (excluding box and slab culverts) not mentioned above, if
required, will be shown on the Drawings.
3204 Materials
(a) Concrete Pipes

In-situ concrete culverts, pre-cast concrete and concrete surrounds to metal culverts shall conform to
the requirements of Series 8000.
Pre-cast concrete pipes used for the construction of culverts shall be manufactured in accordance with
the requirements of AASHTO M 170M (ASTM C 76 or ASTM C 118) or AASHTO M-242 and shall be of
the Class described in the Contract.
Concrete used for the construction of culverts shall be Class C 30/20 in accordance with the
requirements of Division 8400.
Reinforcement used for the construction of pre-cast or in-situ concrete culverts shall be steel
reinforcement complying with the requirements of Division 8300.
(b) Corrugated Metal Pipes

Corrugated metal pipe sections used for the construction of culverts shall be manufactured in
accordance with the requirements of AASHTO M-36 from material which shall have a minimum yield
2
strength of 229 N/mm . Nuts and bolts shall comply with the requirements of AASHTO M-167.

Fabricated under-drain pipes from steel sheets shall have a minimum thickness of 1.32mm. Any class
of perforation specified in AASHTO M 36M is permitted.
Coatings for corrugated metal pipes shall be:
 Galvanized zinc coatings complying with the requirements of AASHTO M 36. Units on which
the zinc coating has been damaged shall be re-galvanized or the surface prepared and
painted with 2 coats of zinc-rich paint.
 Bituminous coatings complying with the requirements of AASHTO M-190.
Coupling bands for zinc coated (galvanized) or aluminium coated (aluminized) corrugated iron or steel
under-drain pipe shall meet the requirements of coupling bands for a Type III pipe of AASHTO M 36.
(c) PVC Drain Pipes

PVC drain pipes shall meet the requirements of AASHTO M 278. The maximum size of pipe shall be
200mm in diameter.
(d) Corrugated Polyethylene Drainage Tubing Drain Pipes

Corrugated polyethylene drainage tubing drain pipes shall meet the requirements of AASHTO M 252.
The maximum size of the pipe shall be 200mm in diameter.
(e) Corrugated Polyethylene Drain Pipes

The corrugations shall form smooth continuous curves and tangents and shall form circumferential
rings about the longitudinal axis of the structure.
3205 Construction Methods

Prefabricated culverts shall be installed under the following conditions:
 Trenched conditions: Where the units are laid in a trench excavated below existing ground
level or in a trench excavated in previously constructed subgrade and, if necessary, sub-base
layers.
 Embankment conditions: Where the units are laid approximately on the existing ground
surface and the subgrade is then constructed on either side and over the culvert.
Unless otherwise approved by the Engineer, all pipe culverts shall be constructed under trenched
conditions.
Surface water must be controlled to prevent storm water from entering the trench.
The Contractor shall make good with bedding materials, any excavation at or below the bottom of the
drainage trenches if the Contractor allows the trench bottom to become soft or otherwise unsuitable for
the construction of the culvert.
3206 Excavation by Trench Method
(a) Depth of Excavation

The Contractor shall first construct the embankment, subgrade and, if necessary, the sub-base to such
a level as will provide a minimum cover above the proposed level of the top of the culvert. Thereafter,
the Contractor may commence excavation of the trench for the culvert.
Where authorised by the Engineer, and particularly in areas of swampy or marshy conditions, the
Contractor may construct the fill to the top of subgrade before commencing excavation for the trench
of the culvert.

The sides of trenches shall be adequately supported at all times. Except where otherwise authorised
by the Engineer, they shall not be battered.
The amount by which the excavation is to exceed the proposed level of the invert of the culvert shall
be sufficient to allow for the type and thickness of bedding material to be placed as specified or as
shown on the Drawings.
(i) Concrete Pipe Culverts

The minimum cover prior to excavation for concrete pipe culverts shall be 250mm or such other
amount required to accommodate the type of bedding required for the pipe in each case.
(ii) Metal Culverts

The minimum cover shall be as specified on the Drawings for the type of metal culvert, or 0.25 times
the diameter of pipes, or 0.25 times the span of pipe arches, whichever is the greater.
The minimum amount by which the excavation is to exceed the proposed level of the bottom of the
pipe shall be 250mm or such other amount required to accommodate the type of bedding required for
the culvert in each case.
(b) Width of excavation

The widths of trenches shall be sufficient to allow for proper laying, bedding and backfilling culverts,
but shall not exceed four-thirds of the external diameter of the pipe(s), plus 400 mm on each side for
single barrel culverts, plus the allowable gap between each pipe for multiple barrel culverts.
If the width of any trench is increased by slipping or collapsing of the trench, the Contractor shall
immediately inform the Engineer and shall not proceed with any further pipe-laying or backfilling until
the Engineer has reviewed the circumstances and provided instructions as to the need for alterations
to the class of pipe or bedding conditions.
Where metal culverts consist of two or more units next to each other, the minimum clearance between
adjacent culverts shall be as shown on the Drawings.
3207 Unsuitable Foundation Conditions

Where the bottom of the trench as excavated does not provide a suitably firm foundation for the culvert
due to soft or otherwise unsuitable material being encountered, the unsuitable material shall be
excavated to a depth below the bottom of the culvert as indicated by the Engineer and replaced with
well compacted gravel or other approved materials to provide a firm earth cushion. When ordered by
the Engineer, the Contractor shall construct a blinding layer of concrete to provide a suitable working
floor.
Other special construction methods shall be shown on the Drawings.
3208 Excavation for Embankment Conditions

Where culverts are to be constructed under embankment conditions as defined in Clause 3205, the
Contractor shall level the existing ground by excavating, filling and compacting as required so that the
foundation for the culvert is true to grade and of uniform density over the whole length of the culvert.
The finished level of the ground on which the culvert is to be bedded shall be below the proposed level
of the underside of the culvert by the same amounts as specified in Clause 3206 (a), for the various
types of culverts.

3209 Disposal of Excavated Material

Where excavated material does not comply with the requirements for backfilling material as specified
hereafter or is surplus to backfilling requirements, such excavated material shall be removed from the
Site and disposed of in approved locations. Material suitable for use in the Works, shall however, be
used as prescribed by the Engineer.
3210 Bedding and Laying of Prefabricated or Cast in-situ Pipe Culverts and
Drains
(a) Concrete Pipe Culverts and Drains

Concrete pipe culverts and drains shall be laid on Class A, B, C or D bedding as shown on the
Drawings and as directed by the Engineer. The pipes shall be laid so as to ensure tight joints between
the pipes. Spigot and Socket pipes and Ogee type pipes must be laid with the spigot ends pointing
downstream. The inside of the pipes shall be smooth with no displaced joints.
All pipes shall be laid true to line and level. The joints shall be sealed on the outside with two layers of
bitumen impregnated hessian. The units shall be butted end to end with butt joints, which shall be
2
covered with two layers of hessian of 340g/m , pre-impregnated with a bituminous emulsion, or a
similar approved material. The strip of hessian shall be at least 150mm wide and placed symmetrically
over the joint. The units shall first be treated with a primer of 60% bitumen emulsion over the width of
the strip of hessian.
(i) Class A Bedding

The pipe shall be laid with the bottom portion on Class C 20/20 concrete of specified thickness below
the lowest part of the pipe and extending upwards on each side of the pipe to a specified proportion of
its height. The thickness of concrete below the pipe and the height to which it is extended upwards
shall be as indicated on the Drawings. Pipes shall be supported on suitably shaped temporary cradles
during concreting. No longitudinal construction joints on the horizontal plane will be permitted.
(ii) Class B and Class C Beddings

The pipe shall be laid on a bedding cradle of compacted selected granular material with a maximum
stone size of 30 mm. The bedding shall extend upwards on both sides of the pipe to a specified
portion of its height, as shown on the Drawings. Joint holes shall be formed in the bedding cradle for
pipe sockets and couplings to ensure that each pipe is fully supported throughout the length of its
barrel on the bedding cradle.
Where unsuitable material beneath the bedding is required to be removed, the voids shall be filled with
the same material as the bedding, compacted in layers according to the specifications.
(iii) Class D Bedding

The pipe shall be laid on the in-situ material in the bottom of the excavation after the excavation has
been hand trimmed to support the pipe along the entire length of its barrel in accordance with the
details shown on the Drawings. Wherever necessary, the in-situ material shall first be stabilised in
accordance with the details shown on the Drawings or as prescribed by the Engineer. Joint holes shall
be formed in the trench bottom for pipe sockets and couplings.
(iv) Rock Foundation

Where rock, shale or other hard material is encountered in the bottom of excavations, construction of
pipes on Class A bedding shall be as follows:
 The material below the pipe shall be excavated and replaced with an equalising bed of sand
or approved gravel or soil to a depth as shown on the Drawings or directed by the Engineer;
 The backfill material shall be watered and compacted to provide a firm earth cushion. Class A
bedding shall then be prepared as described in sub-clause (a)(i) of this Clause.
(v) Concrete Casing

Where shown on the Drawings or ordered by the Engineer, pipes shall be fully encased in Class C
20/20 concrete with the dimensions as shown on the Drawings or as ordered by the Engineer.
Temporary supports shall be provided near the pipe ends to support the pipes during placing of the
concrete. The placing of concrete shall be such that all voids under the pipe are completely filled. Use
shall be made of poker vibrators to ensure proper filling of all voids under and around the pipes with
concrete. The concrete casing shall be cast in one continuous operation until completed.
(b) Metal Culverts

The excavation shall be trimmed to the contour of the invert of the culvert and shaped to enable the
culverts to be bedded as shown on the Drawings.
Where rock is encountered, the depth of excavation shall extend to a depth of at least 325mm below
the contour of the culvert and filled with granular material.
The culverts shall be installed in accordance with the manufacturer's recommendations as approved
by the Engineer. Anchor bolts where specified or shown on the Drawings shall be installed at the ends
of metal pipe culverts in accordance with the manufacturer's instructions to tie them to inlet and outlet
head walls.
(c) Extension of Existing Culverts

Where an existing culvert requires extension or portal replacement, the new section shall be placed at
the same grade and, where it joins the existing structure, at the same level as the existing structure.
Any sections of the existing wing walls, approach slabs and head walls, which may obstruct any new
work, shall be demolished and removed. Existing culvert ends shall not be damaged. Should damage
occur, the repair work shall be done before the placement of any fresh concrete or new culverts. Loose
material shall be removed and joint faces thoroughly cleaned to the satisfaction of the Engineer.
Jointing shall be done in accordance with Clause 8704.
After completion of the extension or partial replacement of a culvert, new approach slabs, head walls,
wing walls, catchpits and other appurtenant structures shall be constructed in accordance with the
Drawings.
(d) Construction of Culverts in Half-Widths in Existing Roads

In the event that construction has to cater for traffic or for any other reason instructed by the Engineer,
culverts shall be constructed in half-widths.
Unless otherwise prescribed, the downstream section shall be constructed first. The end of the
excavation adjoining the traffic lane shall be properly supported to prevent displacement.
Where the culvert is constructed in an existing road and it has been so prescribed by the Engineer, the
pavement layers at least shall be benched and re-compacted during backfilling. The depth of benching
shall equal the respective layer thicknesses, and the width shall be at least 150mm.
(e) General
Construction of culverts shall begin at one end, the position of which shall be fixed as shown on the
Drawings or as directed by the Engineer. The position of the other end of the pipe shall normally be
determined by the end of the last whole unit, the top of which breaks through the fill slope. However, in
the case of skew culverts or culverts with a cover of less than 0.5m at the shoulder, the Engineer may
order that the end unit be cut to the length and skew required.

Any units which deform or crack, or which are not constructed to the required lines, levels and grades,
or which become displaced in the process of the work or during the Defects Liability Period, shall be
removed and replaced by the Contractor.
Pre-cast units shall be lifted and handled by means of approved lifting devices only. Lifting eyes shall
be caulked with a suitable mortar after the units are installed.
The Contractor shall exercise due care not to damage, overstress or displace any prefabricated pipes
with his own traffic or compaction equipment. Where loads in excess of those prescribed in the
Contract are likely to pass over completed culverts, the Contractor shall take appropriate measures to
ensure that the design stresses on the pipes are not exceeded.
3211 Backfilling of Prefabricated Culverts and Storm-water Drains

After the pipes have been firmly laid on the required bedding as described in Clause 3210, backfilling
shall be carried out as follows:
 The material used for the backfilling of those portions of culverts or pipes subject to traffic
loads shall be selected material of at least sub-base quality. Where the excavated material is
not of adequate quality, selected material shall be imported for this purpose.
 Metal culverts shall be temporarily ballasted during backfilling to prevent them from lifting.
 Backfilling alongside and over all pipes shall be placed and compacted in layers not exceeding
150mm after compaction, to a density of at least the density required for the material in
adjoining layers of fill, subgrade and sub-base. The density of backfilling in excavations made
in the natural ground shall be at least 90% of modified AASHTO density. Backfilling shall be
carried out simultaneously and equally on both sides of a pipe to avoid any unequal lateral
forces.
 Where the Engineer so directs, metal culverts with large diameters or spans, or culverts with
multiple openings, shall be constructed under embankment conditions as defined in
Clause 3205. In such cases, the backfilling shall be carried out to the same standard as
described in the previous bullet, simultaneously and equally on both sides of the culvert and
over the culvert until the minimum specified cover is obtained. The width of backfill on each
side of the culvert, after completion, shall be at least equal to the diameter (or span) of one of
the openings of the culvert.
 Metal culverts shall be backfilled symmetrically to prevent distortion of the units and the
Contractor shall also ensure that the required cover, as specified in sub-clause 3206 (a), is
provided over the culvert before allowing construction equipment and vehicles and other traffic
across the culvert.
 Whenever specified or as may be instructed by the Engineer, the backfilling shall consist of
concrete placed between the side of the culvert and the excavation up to the top of the culvert.
 When specified or ordered by the Engineer, the backfilling of culverts shall be done using a
wet or a stiff mixture of soil cement in lieu of a compacted gravel or lean concrete. A wet
mixture of soil cement shall consist of an approved soil or gravel mixed with 5% of Portland
cement and only sufficient water to give a consistency that will permit the soil cement to be
placed with vibrators so that all voids between the pipes and the sides of excavations and
between culverts in the case of multi-barrel culverts will be properly filled. A stiff mixture of soil
cement shall contain 3% of Portland cement and just sufficient water for it to be placed and
compacted like ordinary backfill material. The height to which the soil cement backfill shall be
taken shall be as prescribed by the Engineer or shown on the Drawings, and any remaining
backfill shall be carried out as described previously for granular materials.

 The aggregate used for soil cement shall preferably be a sandy material but may contain
larger particles up to 37.5mm, and shall not have a plasticity index exceeding 10. Detrimental
percentages of silt or clay shall be avoided, and the aggregate shall be obtained from an
approved source.
 The soil cement shall be mixed on the site with suitable concrete mixers, and the water and
cement contents shall be carefully controlled. The material shall be placed and then
thoroughly compacted so that all voids are filled. At culvert ends, stones shall be packed to
prevent the soil cement from flowing beyond the required limits.
 Soil cement shall not be used for backfilling corrugated metal culverts.
3212 Inlet and Outlet Structures

Inlet and outlet structures for culverts shall be constructed in accordance with the details shown on the
Drawings.
(a) Excavation and Backfilling

Excavation and backfilling work shall be carried out in accordance with the provisions of Clauses 8105
and 8108.
(b) Concrete Work

Concrete work shall be carried out in accordance with the provisions of Series 8000. Unless otherwise
specified, all concrete shall be Class C 20/20.
3213 Removal of Existing Work

Where shown on the Drawings, or where directed by the Engineer, existing inlets or outlets to pipe
culverts shall be broken down or demolished and the debris removed from Site. Existing pipes shall
be removed where necessary and all such works shall be carried out in a manner to prevent damage
to existing work that is to remain.
Undamaged pipes shall be reused in the Works where indicated by the Engineer. Pipes which cannot
be reused shall remain the property of the Employer and shall be stacked within the road reserve or
where directed by the Engineer.
Attention is drawn to the provisions in Series 2000 which specifies the structures that have to be
removed as part of the clearing and grubbing operations which will therefore not be measured and
paid under this Division.
3214 Joining New Work to Old

Where partial demolition is required for extension work to existing structures, the contact face shall be
cut to predetermined lines and levels, any loose and fragmented material shall be removed, and
projecting steel cleaned and bent as directed by the Engineer. Where only extension work is required
without partial demolition, the contact surface shall be roughened and cleaned of all dirt and loose
particles.
If dowels are required, they shall be installed in holes drilled into the existing structure, in accordance
with the details shown on the Drawings, and secured by means of an approved type of epoxy resin
grout.
Fresh concrete shall be bonded to the old concrete in accordance with the requirements specified in
Series 8000.
3215 Service Ducts

Where required, the Contractor shall construct service ducts for the easy installation and maintenance
of existing, new and future cables and other services. The pipe shall be laid at 500m intervals in urban
and semi-urban areas across the carriageway and at all side roads. Service ducts shall be constructed
from one or more of the following materials:
 Normal-duty uPVC pipes in accordance with AASHTO M278;

 Reinforced concrete pipes in accordance with AASHTO M170M.
The actual type of pipe required shall be in accordance with the Particular Specifications and the
Drawings. The pipes shall be installed in the required positions and accurate records shall be kept
regarding the depth, position and number of pipes installed in each duct. Pipes shall be laid at the
grades shown on the Drawings to facilitate flushing with water and shall, where required, be encased
in concrete or soil cement.
The width of excavation for service-duct trenches shall be equal to the nominal inside diameter of the
pipe, plus 150mm on each side of the duct. Where ducts consist of two or more units, the minimum
spacing between the units shall be 75mm, and the 150mm side clearance shall apply to the outside
units of the group.
Below the carriageway the depth of excavation shall accommodate a minimum cover of 1m above the
upper side of the installed service duct.
All pipes shall be joined with watertight proprietary couplings made from the same material as the
pipe.
Split pipes shall normally be used only for providing ducting for existing services which cannot be
severed and threaded through the ducts. The pipes shall be accurately cut longitudinally in two halves
and opposite halves shall be matched as sawn. Split pipes shall be placed around the service as
required, firmly bound by steel straps and if required, encased in concrete.
Excavating, laying and bedding the pipes shall be in accordance with the Specifications for
prefabricated culverts with any modifications as may be necessary or specified in this Clause.
Duct ends shall be provided with suitable conical wooden stoppers to prevent dirt from entering the
ducts. Two strands of galvanized steel wire, 2.5mm in diameter, shall be threaded through each unit,
extended 2m beyond each end, and firmly wedged into position with the wooden stoppers.
The end of each duct shall be marked with a marker block constructed to the details shown on the
Drawings. Each duct marker block shall be at least 50mm proud of the finished surface level.
3216 Culverts on Steep Gradients

Where culverts are constructed on gradients exceeding 1 in 4, they shall be referred to as inclined
culverts. Inclined culverts shall be constructed from the type of unit required, normally either circular
concrete pipe units or metal culvert units as described in Clause 3203.
Particular care shall be taken to protect excavations against stormwater damage. The trenches shall
be excavated down to firm ground. If it is necessary to over-excavate to obtain a firm floor, the over-
excavation shall be backfilled with selected gravel or concrete.
After the outlet structure has first been completed, the culvert units shall be laid in the normal manner
by starting from the lower end and placing successive units firmly against each other to prevent
subsequent movement. The lower unit shall be securely cast into the outlet structure, and metal
culverts shall be provided with the necessary anchor bolts at both inlet and outlet structures as well as
at all thrust and anchor blocks.

Thrust and anchor blocks shall be constructed from concrete as required in accordance with the
Drawings and details furnished by the Engineer. Anchor bolts, straps and other anchoring devices
required at anchor and thrust blocks shall be provided.
The backfilling of trenches shall be done in horizontal layers starting at the lower end.
3217 Stormwater Ducts and other Closed Conduits

The specifications given in this Division for culverts, shall apply mutatis mutandis to the construction of
stormwater ducts or any other closed conduits constructed from the prefabricated units described in
Clause 3203, whether intended for drainage or for any other purpose.
3218 Manholes, Outlet Structures and Cleaning Eyes

Manholes, outlet structures and cleaning eyes for culverts shall be constructed in accordance with the
details shown on the Drawings or in locations as instructed by the Engineer.

Item 32.01 Excavation

3
(i) 0 to 1.5 m. ......................................................................................... cubic metre (m )
3
(ii) 1.5 m to 3.0 m .................................................................................. cubic metre (m )
3
(iii) > 3 m in increments of 1.5 m ........................................................... cubic metre (m )
b) Extra over sub item 32.01(a) for excavation in hard material, irrespective of depth ...................
............................................................................................................................ cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated within the specified widths
over the lengths and depths authorised by the Engineer. Excavation in excess of the widths specified
or authorised by the Engineer shall not be measured for payment.
When measuring excavation for removal of existing culverts, the volume occupied by the culvert shall
not be subtracted from the calculated volume of excavation.
In case of manholes and catchpits, the dimensions for determining the volume of excavation shall be
the neat outside dimensions of the structure, plus an allowance of 0.5m of working room around the
structure.
The tendered rate shall include full compensation for all excavation; temporary timbering, shoring and
strutting; preparing the bottom of the excavation for the culvert beds; disposal of excavated material
unsuitable for backfilling; keeping the excavations safe; dealing with any surface or sub-surface water;
and for any other operations necessary to complete the work as specified.
Payment shall distinguish between soft and hard material as defined in Clause 3109.
Item 32.02 Backfilling

a) Using the excavated material ............................................................................. cubic metre (m³)
b) Using imported selected material ...................................................................... cubic metre (m³)

c) Extra over sub-items 32.02(a) and (b) for soil cement backfilling (percentage of cement indicated)
............................................................................................................................ cubic metre (m³)
The unit of measurement shall be cubic metre of material in place after compaction and the quantity
shall be calculated from the specified dimensions of the backfilling or as authorised by the Engineer.
If excavations are carried out in excess of the dimensions authorised by the Engineer, the quantity of
backfilling will nevertheless be based on the authorised dimensions. The volume occupied by the
culvert or pipe shall be subtracted when calculating the volume of backfilling.
Payment at tendered rates shall include full compensation for backfilling under, alongside and over
conduits; and for watering and compacting the backfill material to the specified density. The tendered
rate for sub-item 32.02(b) shall, in addition, include full compensation for supplying and transporting
selected material of sub-base quality from approved sources.
The tendered rate for sub-item 32.02(c) shall be additional to the rates tendered for sub-items 32.02(a)
and (b) and shall include full compensation for all incidentals required for the complete backfilling with
soil cement as specified.
The cost of backfilling of excavations for manholes, catchpits and structures after construction will not
be paid for, and the Contractor shall allow for backfilling around manholes, catchpits and structures in
his price.
Item 32.03 Concrete pipe culverts

a) On Class A bedding (type, length and diameter indicated) ................................ linear metre (m)
b) On Class B bedding (type, length and diameter indicated) ................................. linear metre (m)
c) On Class C bedding (type, length and diameter indicated) ................................. linear metre (m)
d) On Class D bedding (type, length and diameter indicated) ................................ linear metre (m)
The unit of measurement for concrete pipe culverts shall be the linear metre of culvert laid as shown
on the Drawings or ordered by the Engineer. The length shall be measured along the soffit of the
culvert.
The tendered rates shall include full compensation for providing; testing; loading; transporting;
unloading the culverts; providing and placing the selected granular material, where required; and for
the installation, laying and jointing of the culverts, as specified.
Should it be required that a section shall be cut from a standard length of concrete pipe unit, the full
standard length of the unit shall be measured for payment. No additional compensation for cutting and
disposing of such section will be paid.
Upon payment, differentiation shall be made between the various types and sizes of culverts and
between the culverts placed on A, B, C and D classes of bedding.
Item 32.04 Metal and other culverts

This item includes metal culverts; PVC drain pipes; corrugated polyethylene drainage tubing drain
pipe; corrugated polyethylene drain pipe; and any other culvert type approved by the Engineer.
a) Size, wall thickness and type indicated .............................................................. linear metre (m)
b) Cutting of bevelled or skew ends (size and type indicated) ..................................... number (No)
The unit of measurement shall be the linear metre of culvert laid as shown on the Drawings or ordered
by the Engineer.

In all cases, the culvert length shall be measured along the pipe centre line. In the case of a metal
pipe arch, the culvert length shall be measured along the bottom of the pipe arch. In both cases the
length of bevelled and/or skew ends shall be included.
The tendered rates shall include full compensation for providing; testing; loading; transporting and off-
loading the culverts/drain pipes; providing and placing fine-grained materials where required for the
installation; and for installing, laying and jointing the culverts as specified. Upon payment, a
differentiation shall be made between the various types and sizes of culverts/drain pipes and also
between culverts with differing wall thicknesses.
Payment shall be made separately for the cutting of bevelled and/or skew ends, and the tendered rate
shall include full compensation for all work in connection with the cutting of ends.
Item 32.05 Extra-over items 32.03 and 32.04 for constructing inclined culverts ....................
............................................................................................................ linear metre (m)
The unit of measurement shall be the linear metre of culvert installed at a grade steeper than 1:4 as
specified in Clause 3216.
The tendered rate shall include full compensation for additional or more difficult work of any nature in
regard to laying, excavating and backfilling as may be required for installing the culverts at a grade
steeper than 1:4.
Item 32.06 Cast in-situ concrete and formwork

a) In Class A bedding, screeds and the encasing for pipes, including formwork (class of concrete
indicated).......................................................................................................... cubic metre (m³)
b) In inlet and outlet structures, skewed ends, catchpits, manholes, thrust and anchor blocks,
excluding formwork but including Class U2 surface finish (class of concrete indicated) ...........
......................................................................................................................... cubic metre (m³)
c) Formwork for concrete under Item 32.06 (b) (type of finish indicated) .......... square metre (m²)
d) In concrete linings for the inverts of metal culverts under Item 32.04, including formwork and class
U2 surface finish (class of concrete indicated) ............................................... cubic metre (m³)
Measurement of formwork and concrete cast in-situ shall be as specified in Division 8200 and 8400 of
these Specifications, except that formwork for pipe beddings and invert slabs shall not be measured
for payment.
Payment for this item for formwork and concrete cast in-situ shall be made in line with the provisions in
Divisions 8200 and 8400 of these Specifications, except that payment for the formwork for concreting
in sub-items 32.06 (a) and (d) shall not be payable separately, and the Contractor's rates for concrete
shall include full compensation thereof.
No separate payment shall be made for the construction of joints in culvert floor slabs or at inlet and
outlet structures and the tendered rates for concrete shall include full compensation for forming the
joints complete in accordance with the details shown on the Drawings.
3
Item 32.07 Concrete backfill for culverts (class indicated) ............................ cubic metre (m )
The unit of measurement shall be the cubic metre. The quantity shall be calculated from the
dimensions of the excavation as specified or as authorised by the Engineer, minus the volume of the
culverts, irrespective of whether the actual excavation to be backfilled exceeds the specified or
authorised dimensions.

Payment shall be made as for concrete in item 32.06(a).
Item 32.08 Prefabricated/Precast concrete inlets and outlets to culverts ......... number (No)
Prefabricated/Precast concrete inlets and outlets for concrete pipe culverts shall be measured by the
number of inlets or outlets, complete in position.
The tendered rate shall include full compensation for procuring, providing, loading, transporting, off-
loading and installing the inlets or outlets as specified.
Item 32.09 Steel reinforcement:

a) Mild steel (grade specified) ............................................................................................. .tonne (t)
b) High tensile steel (grade specified) ................................................................................. tonne (t)
c) Mild steel mesh ....................................................................................................kilogramme (kg)
d) High tensile steel mesh........................................................................................kilogramme (kg)
Measurement and payment for steel reinforcement under this item shall be made in line with the
provisions of Division 8300 of these Specifications.
Item 32.10 Dowels for joining old and new concrete ......................................kilogramme (kg)
The unit of measurement shall be the kilogramme of steel dowels installed.
The tendered rate shall include full compensation for supplying all materials; all cutting, drilling and
grouting; and any other operations or activities necessary for the proper execution of the work.
Item 32.11 Removal, stacking and relaying

a) existing pipes (size and type of bedding indicated) ............................................. linear metre (m)
b) existing prefabricated culverts (type and size indicated) ..................................... linear metre (m)
The unit of measurement shall be the linear metre of pipe or existing prefabricated culverts removed,
stacked and relayed.
The tendered rate shall include full compensation for lifting, loading, transporting to stack, off-loading,
stacking and relaying the pipes and/or prefabricated culverts.
Payment for any excavation and backfilling required for removing, transporting, stacking and relaying
the existing pipes and prefabricated culverts shall be made separately under items 32.01 and 32.02.
Where existing pipes are loaded, transported and used in temporary diversions, they shall not be
measured for payment under this item, but payment thereof shall be made in terms of Division 1500,
item 15.01.
Item 32.12 Treating surfaces with epoxy resin for joining new to old concrete (type of epoxy
resin specified) ................................................................................................. litre (ℓ)
The unit of measurement shall be the litre of epoxy resin compound used at the specified rate of
application.
The tendered rate shall include full compensation for procuring the epoxy resin, applying the material
and for all other additional work and incidentals required for treating the surface as specified.

Item 32.13 Protective mastic asphalt coating for corrugated metal culvert units (state
2
whether to be applied by brush or by spray gun) ..................... square metre (m )
The unit of measurement shall be the square metre of protective coating applied as specified and as
directed by the Engineer. When both inside and outside surfaces are treated, the area of both surfaces
shall be measured.
The tendered rate shall include full compensation for procuring and furnishing the mastic asphalt,
applying the material, and for all other additional work and incidentals required for providing the
protective coating as specified.
Item 32.14 Manhole and catchpit structures complete

a) Manholes (type indicated) ......................................................................................... number (No)
b) Catchpits (type indicated) ........................................................................................ number (No)
c) Extra over or less than sub-item 32.14(a) for variations in the depths of manholes from the
standard depth designated for tendering purposes (standard depth and type of manhole
indicated).............................................................................................................. linear metre (m)
d) Extra over or less than sub-item 32.14(b) for variations in the depths of catchpits from the
standard depth designated for tendering purposes (standard depth and type of catchpit indicated)
............................................................................................................................. linear metre (m)
The unit of measurement, in the case of sub-items (a) and (b), shall be the complete unit as shown on
the Drawings, including all concrete, brickwork, covers, frames, grids, step-irons and other
accessories.
The tendered rates shall include full compensation for procuring, furnishing, transporting, installing,
and laying, where applicable, the complete units except for excavation and backfilling, which shall be
measured separately. The tendered rate shall also include full compensation for the connection to and
building of, any conduits into the walls of the various structures.
The unit of measurement in the case of sub-items (d) and (e) shall be the linear metre of increased or
decreased depth of the manhole or catchpit measured in relation to the standard depth furnished for
tendering purposes.
The tendered rate per metre shall be an adjustment to the compensation for the standard item,
payable either as an increased compensation to the Contractor in the case of an increased depth, or
as a decrease in compensation in the case of a decreased depth in relation to the standard depth.
Any cast in-situ concrete and formwork shall be measured and paid under sub-items 32.06(b) and (c)
respectively, with any additional excavation paid under item 32.01, and backfilling under item 32.02.
Item 32.15 Anchors for pipes (description) ............................................................ number (No)

The unit of measurement shall be the complete anchor installed, including straps, bolts, etc, but
excluding any in-situ concrete work, which shall be measured under sub-item 32.06(b) and (c).

Item 32.16 Service ducts

a) Ordinary pipes (type and diameter indicated) ..................................................... linear metre (m)
b) Split pipes (type and diameter indicated) ............................................................ linear metre (m)
The unit of measurement shall be the linear metre of service duct laid.
The tendered rates shall include full compensation for procuring, providing and laying the pipes,
including end stoppers, draw wires and complete installation, but shall exclude excavation (under
item 32.01), backfilling (under item 32.02), and encasing with concrete (under sub-items 32.06(a)),
which shall be measured for payment under the relevant items shown.
Item 32.17 Duct marker blocks (type indicated) .................................................. number (No.)
The unit of measurement shall be the number of marker blocks installed and the tendered price shall
include full compensation for the manufacture, delivery and installation of the marker blocks, complete
as shown on the Drawings.
Item 32.18 Chambers for ducts ............................................................................... number (No.)

The unit of measurement shall be the number of chambers.
All tendered rates shall include full compensation for procuring, furnishing all materials and for
constructing the chambers complete.
Item 32.19 Hand excavation to determine the positions of existing services .........................
3
........................................................................................................... cubic metre (m )
The unit of measurement shall be a cubic metre of material excavated within the lengths and widths
authorised by the Engineer and to the depth required to expose the service.
Excavation in excess of the authorised dimensions shall not be measured for payment.
The tendered rate shall include full compensation for all excavation; backfilling; compacting to 90% of
modified AASHTO density; transporting and disposing of any surplus excavated material; keeping the
excavations safe; dealing with any surface or subsurface water; taking special care to ensure that
services are not damaged in any way; and any other operation necessary for completing the work.
Any damage to a service caused by the Contractor shall be repaired at the Contractor’s own cost, to
the satisfaction of the owner of the service and the Engineer.
No distinction shall be made between hard and soft material, neither will distinction be made between
the various types of services to be exposed or the depths to which excavations are taken.
Item 32.20 Reinstating trenches crossing roads

a) Selected layers .................................................................................................square metre (m²)
b) Sub-base ..........................................................................................................square metre (m²)
c) Base (including prime coat) ..............................................................................square metre (m²)
d) Bituminous surfacing (including tack coat) .......................................................square metre (m²)
e) Kerbing ................................................................................................................ linear metre (m)
The unit of measurement for sub-items (a) to (d) shall be the square metre of the layer reinstated
where instructed by the Engineer.
The unit of measurement for sub-item (e) shall be the linear metre of kerbing replaced due to trench
excavations where instructed by the Engineer.

Any reinstatement required beyond the agreed or instructed dimensions due to damage caused by the
Contractor will not be measured for payment.
The appropriate Divisions of the Specifications shall also be applicable to the reinstatement of the
trenches.
The tendered rates shall include full compensation for procuring, furnishing, placing, compacting and
finishing all materials; providing all labour and construction plant; cutting and preparing the edges of
the existing surfacing; and protecting and maintaining the completed reinstatement as specified.
Item 32.21 Prefabricated reinforced concrete skew end units for concrete culverts
constructed at a skew angle (type and dimensions of unit and class of bedding
indicated) ................................................................................................. number (No)
The unit of measurement shall be the number of each type and size of prefabricated reinforced-
concrete skew end unit provided and installed, irrespective of the angle of skew.
The tendered rates shall include full compensation for providing, transporting, testing, loading and
unloading the units; constructing the prescribed class of bedding; and for installing, laying and joining
the units, complete as specified and in accordance with the details shown on the Drawings.

Division 3300: Kerbing, Channelling, Open Chutes, Downpipes, and

Lining of Open Drains
3301 Scope
This Division covers the construction of concrete kerbing and channelling; kerb inlets; chutes and
downpipes; reinforced concrete drain covers; and masonry and concrete linings for open drains at the
locations and to the details as shown on the Drawings, or as directed by the Engineer.
3302 Kerbing and Channelling

Kerbing may include barrier kerbs which are mountable or semi-mountable types. All these elements
may be precast units or constructed in a continuous operation using slip-form construction.
Channelling may be formed in-situ, using fixed-form or slip-form construction. The concrete lining of
open channels shall be cast in-situ or pre-cast concrete.
(a) Dimensions
Kerbing and channelling shall be provided and constructed in accordance with the details, dimensions,
lines and levels shown in the Contract or as directed by the Engineer.
(b) Material Requirements for Kerbing and Channelling
(i) General
Kerbs shall be of natural stone, concrete or asphalt, as described in the Contract. Natural stone and
precast concrete kerbs shall have a maximum length of 1m and a minimum length of 400mm.
The ends of all natural stone and precast concrete kerbs shall be at right angles to the longitudinal
axis of the element.
(ii) Natural Stone

Natural stone shall be obtained from cutting or blasting limestone, sandstone, or granite from an
approved source. Unless otherwise directed one type of stone shall be used for a particular section.
Stone with visible drill marks or holes on the exposed faces shall not be used.
Natural stone shall be sawn or dressed to the cross-sectional profiles shown in the Contract.
(iii) Concrete for Kerbing and Channelling

Concrete for kerbing and channelling shall be Class C 25/20 concrete complying with the requirements
of Division 8400 of these Specifications.
Precast concrete kerbing and channelling shall comply with the requirements of BS 340, or Class C
25/20 when not specified. In-situ channelling shall be of the class of concrete indicated.
Concrete for foundations and backing shall be Class C 20/20 concrete complying with the
requirements of Division 8400, except where foundations and backing are cast monolithically with the
kerbing and channelling, in which case it shall be Class 25/20. Curing of the completed foundation
shall be carried out in accordance with the requirements of Clause 8410.
Concrete shall not be placed during rain. Surface water shall not be allowed to come into contact with
the freshly compacted concrete.

(iv) Mortar for Bedding of Kerbing and Channelling

Mortar for bedding shall be a semi-dry mixture of three (3) parts by volume of fine aggregate
complying with the requirements of sub-clause 8402 (c) to one (1) part by volume of cement complying
with the requirements of sub-clause 8402 (a).
(v) Water for Kerbing and Channelling

Mixing water for concrete and mortar shall be water quality Type A as stipulated in sub-clause 8402
(d).
(vi) Asphalt Kerbing

The constituents of the asphalt mix shall be 60-70 penetration grade bitumen complying with the
requirements of Sub-clause 6403(a), and aggregates complying with the requirements of sub-clause
6403(b). The percentage of binder by mass of the total mixture shall be between 6 and 9 percent. The
nominal size of aggregate shall not exceed 20mm.
The mix shall be designed by the Contractor within the above limitations. The Contractor shall carry
out trial mixes of the asphaltic composition using the same plant as will be used in the Works to the
satisfaction of the Engineer. When a proposed mix has been approved, no variations shall be made in
the mix proportions or in the type, size, grading or source of any of the constituents without the
agreement of the Engineer, who may require further tests to be undertaken.
(c) Construction Requirements for Kerbing and Channelling
(i) General
Natural stone kerbs shall be laid on separately constructed foundations.
Concrete kerbing and channelling shall be of either precast elements laid on separately constructed
foundations, or constructed in-situ between fixed or sliding side-forms.
Asphalt kerbs shall be constructed in-situ.
(ii) Equipment
Equipment for constructing in-situ concrete kerbing and channelling shall be purpose-made slip-form
or extruding equipment approved by the Engineer.
Equipment for constructing asphalt kerbs between sliding forms shall be purpose-made extruding
equipment approved by the Engineer.
(iii) Excavation for Foundations

Foundations for natural stone, precast and in-situ concrete kerbing and channelling shall be excavated
to the required width and depth indicated in the Contract, and all unsuitable material shall be removed
and replaced with a layer of approved bedding material at least 75mm thick.
The bedding shall be compacted and accurately shaped to the required grade. No concrete shall be
placed on uncompacted or disturbed material.
The sides and bottom of excavations shall be neatly trimmed to the lines and levels described in the
Contract and any unsuitable material shall be removed and replaced with approved granular material
compacted to a density of not less than 95% of the maximum dry density when determined in
accordance with AASHTO T-180.
The bottom of excavations shall be compacted to a density of not less than 95% of the maximum dry
density when determined in accordance with AASHTO T-180.
(iv) Laying Natural Stone or Pre-cast Concrete Kerbing and Channelling

Mortar complying with the requirements of Clause 8904 (c) shall be evenly spread on the concrete
foundations to the required thickness.

Kerbing and channelling shall be placed vertically to line and level on the mortar bed relative to a
guide-line fixed along the top front edge of the kerb; and firmly tamped into position. Each kerb laid
shall be firmly abutted against the end of the previously laid kerb.
Kerbs laid on horizontal curves shall be either purpose-made radius kerbs or 400mm long straight
kerbs.
Prior to the placing of the backing concrete, the laid kerbs shall be approved by the Engineer.
Backing concrete shall be placed against the back of the laid kerbing and channelling, and shall be
lightly compacted by hand to the satisfaction of the Engineer. The backing concrete shall be cured with
hessian and polythene sheeting for a minimum period of four (4) days.
Natural stone or precast concrete kerbing and channelling shall not be damaged during transport or
laying. Broken or spalled elements shall not be used and shall be removed and replaced by
undamaged elements.
The kerbs and channels shall be constructed true to line and elevation and shall have a neat
appearance. Where transverse cracks occur, the Contractor shall replace the entire section between
the contraction joints.
(d) Cast In-Situ Concrete Kerbs and Channels

Cast in-situ concrete kerbs and channels may be cast monolithically with the foundation and/or
backing.
Formwork shall consist of materials as specified in Division 8200.
Concrete for cast in-situ concrete kerbs and channels shall be mixed, transported, placed and
compacted in accordance with the requirements of Division 8400.
Forms shall be placed to line and level indicated by a guide-line accurately fixed along the top front
edge of the kerb.
Kerbs constructed on horizontal curves shall be constructed using either purpose-made radius forms
or straight forms not exceeding 400mm in length.
Forms shall be removed from any concrete surfaces that will be exposed, within a period of 24 hours
of the concrete having been placed. Minor defects shall be repaired with 2:1 sand/cement mortar.
Plastering shall not be permitted on exposed faces and all rejected portions shall be removed and
replaced at the Contractor's expense. When completed, the sections shall be cured in accordance with
the requirements specified in Clause 8410.
The completed kerbs and channels shall be true to line and elevation and shall have an even and neat
appearance.
Joints shall be constructed at intervals not exceeding 3m and at right angles to the longitudinal axis of
the completed kerb either by wet-forming in the plastic concrete or by sawing in the hardened concrete
in a manner approved by the Engineer.
Curing of the completed kerb shall be carried out in accordance with the requirements of Clause 8410.
Concrete kerbs and channels shall not be placed during rain. Surface water shall not be allowed to
come into contact with the freshly compacted concrete.
(e) Cast In-Situ Concrete Kerbs and Channels (Sliding Forms)

Kerbs and channels may be constructed in-situ between sliding forms either on previously constructed
foundations, or monolithically with the foundations and/or backing.

Slip-form or extruding machines used for constructing in-situ kerbs shall be electronically guided for
line and level along a guide-line accurately fixed relative to the finished line and level of the kerbs and
channels.
The guide-line shall be off-set at a constant height above, and parallel to, the top edge of the kerbs
and channels to an accuracy that will ensure compliance with the tolerances given in this Division. The
guide-line shall be supported from stakes not more than 5m apart by connectors capable of fine
adjustment. The spacing of stakes on horizontal curves shall be appropriate to the radius of the curve.
The guide-lines/wires shall be supported from stakes not more than 8m apart by connectors capable
of fine horizontal and vertical adjustment. The guide-lines shall be tensioned on the stakes so that a
500g weight shall produce a deflection of not more than 20mm when suspended at the midpoint
between any pair of stakes. The ends of the guide-lines shall be anchored to fixing points which shall
not be closer to the edge of the slab than the row of stakes and in no circumstances shall a guide-line
be anchored to a stake.
The stakes shall be positioned and the connectors maintained at their correct height and alignment
from 12:00 hours on the day before concreting takes place until 36 hours after the concrete has been
finished. The guide-line/wire shall be erected and tensioned on the connectors at any section for at
least two (2) hours before concreting that specific section.
The Contractor shall submit to the Engineer, for his approval of line and level; the stakes, connectors
and guide-lines/wires which are ready for use alongside the length of slab to be next constructed, by
09:00 hours on the working day prior to the day on which the slab is to be constructed. Any
deficiencies, which are notified by the Engineer, shall be rectified by the Contractor who shall then
reapply for the approval of the affected stakes. Work shall not proceed until the Engineer has given his
approval. If any deficiencies are rectified by the Contractor and approved by the Engineer before
18:00 hours, or such later time agreed by the Engineer, the Contractor may proceed with construction
the next day. Otherwise the Contractor shall resubmit any rectified stakes for approval on the next day.
Concrete for in-situ concrete kerbs and channels constructed between sliding forms shall be mixed
and transported in accordance with the requirements of Division 8400.
Kerbs and channels constructed between sliding forms shall have a Class F2 formed surface finish in
accordance with the requirements of Clause 8205.
Concrete shall be provided to the slip-form or extruding machine at such frequency as will enable the
machine to move forward continuously at the planned rate of progress.
Joints shall be constructed at intervals not exceeding 3m and at right angles to the longitudinal axis of
the completed kerb either by wet forming in the plastic concrete or by sawing in the hardened concrete
in a manner approved by the Engineer.
Curing of the completed kerbs and channels shall be carried out in accordance with the requirements
of Clause 8410.
Concrete kerbs and channels shall not be placed during rain. Surface water shall not be allowed to
come into contact with the freshly compacted concrete.
(f) Cast In-Situ Asphalt Kerbs

The materials shall be weighed and measured into a mechanical mixer and thoroughly mixed so that
all particles of the aggregate are completely and uniformly coated. The temperature during mixing
shall be within the range 165 – 185ºC.

The kerbs shall be laid on a tack coat complying with the requirements of Division 6200 as soon as
practical after the completion of the surface on which they are to be laid. The asphalt kerb shall firmly
adhere to the underlying surface.
Asphalt kerbs shall not be placed during rain.
(g) Construction Sequence
(i) Where Kerbs and Channels are Constructed before the Base
In this case slip-form units or cast in-situ units may be constructed. During working and constructing
the base, precautionary measures shall be taken to prevent the concrete work from being damaged or
displaced.
(ii) Where Kerbs and Channels are Constructed after the Base
The base shall be constructed wider than the specified width, after which a neat trench shall be dug for
the kerbing or channelling. Any over-excavation shall be filled with concrete cast simultaneously with
the kerbing and channelling.
(iii) Where Kerbs and Channels are Constructed after the Asphalt Base and/or Asphalt Surfacing
The asphalt base and/or asphalt surfacing shall be constructed wider than the specified width and
shall then be cut back accurately with a mechanical saw to a marked line to give a neat joint-line
between the kerbs and channels and the asphalt layer. The base shall then be removed to the
required depth.
Any concrete spilt onto the asphalt surface shall be removed. Where so required by the Engineer, the
Contractor shall, without any additional compensation, paint emulsion over the stained surface.
3303 Open Chutes and Linings for Open Drains

Open chutes and linings for open drains shall be constructed to the lines, gradients and cross sections
shown in the Contract or as instructed by the Engineer.
(a) Material Requirements for Open Chutes and Concrete Linings for Open Drains
(i) Concrete
Concrete used for the construction of open concrete chutes and concrete linings for open drains shall
be Class C 20/20 in accordance with the requirements of Division 8400.
(ii) Reinforcement
Reinforcement used for the construction of open concrete chutes and concrete linings for open drains
shall be steel reinforcement complying with the requirements of Division 8300.
(iii) Masonry and Stone Pitching

Masonry and stone pitching used for the construction of open chutes and linings for open drains shall
be Class B in accordance with the requirements of Division 8900.
(iv) Concrete Drain Covers

Concrete drain covers can be constructed with cast in situ or pre-cast concrete as shown in the
drawings.
Formed concrete surfaces shall be Class F2 while unformed concrete surfaces shall be Class U2.”
The surface of concrete drain covers shall be true to the line and shall be stable. Where any cover(s)
are found to move under the application of light pressure, such as is applied by walking along the
covered drain, these shall be rejected and the Contractor shall proposed a method of re-setting the
covers on the drain so as to obtain the specified condition.”

(b) Construction Requirements for Open Chutes and Linings for Open Drains
(i) Excavation and Preparation of Bedding

The Contractor shall take the utmost care to avoid excavation below the required levels. Any
excavation carried out below the required level due to over excavation or removal of unsuitable
material or the presence of voids, shall be reinstated by placing and compacting with suitable material
(ii) Concrete, Stone-Pitching and Masonry Linings

The excavation work for open drains shall be executed in accordance with the provisions of Clause
3103 and Division 4200.
The excavations shall be neatly trimmed to the lines and levels specified so as to permit the accurate
construction of the concrete linings. All loose material shall be compacted to a density of not less than
93% of modified AASHTO density.
Where the in-situ material is unsuitable, the Engineer may order that it be removed to the required
depth and replaced with selected material compacted to a density of 93% of modified AASHTO
density.
Where excavations for open drains are in rock, over-break shall be backfilled as instructed by the
Engineer; either with mass concrete or with selected natural gravel or soil compacted to a modified
AASHTO density of at least 93%.
Stone-pitching and masonry linings shall be constructed in accordance with the provisions of 3403.
(iii) Chutes
Excavations for chutes shall be neatly trimmed. All loose material shall be thoroughly compacted, and
where over-break occurs in hard material, the excavations shall be backfilled with mass concrete. If
required by the Engineer, the excavations shall be taken deeper to accommodate a concrete screed
cast to act as a working platform for the construction of the chutes.
Prefabricated chutes shall be manufactured in accordance with the dimensions shown on the
Drawings, and the units shall fit neatly into each other as shown.
The bottom unit shall rest against the outlet structure or footing as shown on the Drawings.
The units shall be laid true to line and grade from the bottom up so that each unit fits neatly into the
previous one.
A transition section shall be constructed at the inlet to lead the water into the chute as shown on the
Drawings.
(iv) Cast In-Situ Chutes on Cut Slopes

Cast in-situ concrete chutes on cut slopes, together with the inlet and outlet structures, shall be
constructed in accordance with the Drawings. The class of concrete shall be as indicated on the
Drawings.
Where required by the Engineer, a concrete screed shall first be cast on excavations that cannot be
trimmed accurately. The screed shall be accurately finished to the level of the underside of the chute
floor slab and allowed to set before the floor slab is cast. Where the material being excavated cannot
be accurately trimmed or where the chute sides have to extend above the surface of the cut slopes,
the outer faces of the sides shall be cast against formwork.
(v) Concrete-Lined Open Drains

The exposed surfaces of the concrete linings of open drains shall be given a class U2 surface finish.
Concrete shall be cured in accordance with the requirements of Clause 8410.

Sealed joints in concrete shall be in accordance with the details indicated on the Drawings and the
provisions of Clause 8408. Cold joints shall be painted with a coat of approved bituminous emulsion
containing 60% of bitumen by mass; or with an approved anti-adhesive before any adjoining slabs are
cast.
Expansion joints shall be made in accordance with the Drawings.
Where required, the surfaces on which a concrete lining is to be cast shall, after having been trimmed,
be covered with polyethylene sheeting 0.15mm thick and all joints in the sheeting shall be overlapped
by at least 150mm.
3304 Inlet and Outlet Structures and Transition Sections

Transition sections on kerbing, kerbing-channelling combinations and concrete-lined channels shall be
constructed to the same standards and using the same methods described for the uniform sections,
but with the required modifications. Sections may be either pre-cast or cast in-situ units.
Inlet and outlet structures may be either pre-cast; or partially pre-cast concrete units; or cast in-situ
concrete.
3305 Construction Tolerances and Surface Finish
(a) Concrete Kerbing and Channelling

Concrete kerbing and channelling shall be constructed to within the following dimensional and
alignment tolerances.
(i) Horizontal Alignment

The maximum deviation of edges, centrelines, or vertical surfaces from specified positions shall be
25mm.
(ii) Vertical Alignment and Level

The inside edge of channelling shall not be above the finished road level; and not more than 10mm
below the finished road surface. The invert level of channels and drains and the top of kerbing shall
not deviate more than 10mm from the required level and no channels or drains shall have adverse
grade.
(iii) Trueness of Exposed Surfaces

When tested with a 3m straight edge, no surface irregularities shall exceed 6mm.
(iv) Cross-Sectional Dimensions

All cross-sectional dimensions shall be within 6mm of the specified dimensions except that the
underside of channelling may extend up to 25mm below the level at which it would have the required
thickness.
(b) Concrete-Lined Channels

Concrete-lined channels shall be constructed to within the following tolerances.
(i) Horizontal Alignment

The maximum deviation from the true position of the edges or centreline shall be 25mm.
(ii) Vertical Alignment

The invert level of concrete-lined open channels shall not deviate more than 25mm from the required
level and the channel invert shall not have an adverse grade.

(iii) Trueness of Exposed Surfaces

When tested with a 3m straight edge, no exposed surface shall show surface irregularities of more
than 10mm.
(iv) Cross-Sectional Dimensions

All cross-sectional dimensions shall be within 10mm of the specified dimensions. The average
thickness of any invert or side slab shall not be less than the specified thickness when considering any
2
complete slab or any slab section having a surface area of 10m or more; and disregarding any
thickness of more than 10mm in excess of the specified thickness.
(c) Surface Finish

All exposed concrete surfaces shall be Class U2 surface finish for unformed work and Class F2
surface finish for formed surfaces.

Item 33.01 Kerbing

a) Concrete kerbing (class of concrete indicated for in-situ concrete) (Descriptions of type with
reference to Drawing) ...................................................................................... linear metre (m)
b) Concrete kerbing (precast) ............................................................................... linear metre (m)
c) Stone kerbing (type of stone indicated) (Descriptions of type with reference to Drawing) ........ .
......................................................................................................................... linear metre (m)
d) Asphalt kerbing ................................................................................................. linear metre (m)
The unit of measurement shall be the linear metre of concrete (in-situ and precast), stone or asphalt
kerbing complete as constructed, measured along the front face of the kerb.
The tendered rate shall include full compensation for the necessary excavation, bedding, backfilling,
formwork, concrete haunching or stone sawing, finishing, and for procuring, furnishing and installing all
materials as specified.
Item 33.02 Kerbing-Channelling combination

a) Concrete (class of concrete indicated for in-situ concrete) (Descriptions of type with reference to
Drawing) ............................................................................................................ linear metre (m)
b) Concrete kerbing (precast) ............................................................................... linear metre (m)
c) Stone (type of stone indicated) (Descriptions of type with reference to Drawing) ......................
.......................................................................................................................... linear metre (m)
d) Asphalt kerbing ................................................................................................. linear metre (m)
The unit of measurement shall be the linear metre of concrete (in-situ and precast), stone or asphalt
kerbing-channelling combination complete as constructed, measured along the front face of the
kerb/channel.
The tendered rate shall include full compensation for the necessary excavation, bedding, backfilling,
formwork, concrete haunching or stone sawing, finishing, and for procuring, furnishing and installing all
materials as specified.

Item 33.03 Chutes

a) Concrete (class of concrete indicated for in-situ concrete) (Descriptions of type with reference to
Drawing) ........................................................................................................... linear metre (m)
b) Stone (type of stone indicated) (Descriptions of type with reference to Drawing) .....................
.......................................................................................................................... linear metre (m)
The unit of measurement shall be the linear metre of completed chute as constructed, including any
overlap measured along the slope as laid but excluding transition sections and inlet and outlet
structures measured and paid separately.
The tendered rate per linear metre shall include full compensation for procuring, furnishing and
installing the completed chutes as specified and for all excavation and the preparation of bedding,
backfilling, formwork and finishing required.
Item 33.04 Cast in-situ concrete chutes

a) Concrete (class indicated) ...............................................................................cubic metre (m³)
b) Formwork (surface finish indicated) ............................................................... square metre (m²)
Measurement and payment under this item shall be for formwork and concrete as specified in
Divisions 8200 and 8400, except that payment for excavation and gravel or soil backfilling shall be
deemed to be included in the rates tendered for concrete and shall not be measured and paid for
separately.
Item 33.05 Inlet, outlet, transition and similar structures (typical designs)
a) Concrete (description of structure, type, etc, with reference to Drawing and class of concrete)
................................................................................................................................ number (No)
b) Stone masonry (description of structure, type, etc, with reference to Drawing) ..... number (No)
The unit of measurement and payment shall be the number of completed units of each type of
structure constructed, and payment shall include full compensation for all formwork, concrete or stone,
excavation, trimming and backfilling, including any accessories such as grids, as may be specified on
the typical Drawings.
Item 33.06 Inlet, outlet, transition and similar structures

a) Concrete (class indicated) ................................................................................cubic metre (m³)
b) Stone masonry (class indicated) ......................................................................cubic metre (m³)
c) Formwork (surface finish indicated) ............................................................... square metre (m²)
The measurement and payment for formwork and concrete under this item shall be as specified in
Divisions 8200 and 8400, except that excavation, trimming and backfilling shall not be measured and
paid for separately, the cost of which shall be deemed to be included in the rates tendered for concrete
and stone masonry works.
Item 33.07 Trimming of excavations for concrete-lined open drains

a) In soft material ............................................................................................... square metre (m²)
b) In hard material .............................................................................................. square metre (m²)
The unit of measurement shall be the square metre of excavation trimmed to receive concrete lining.

The tendered rates shall include full compensation for all labour, plant, materials and other additional
work and incidentals necessary for trimming the excavations for open drains to the standard of finish
required for the construction of concrete linings.
All excavation, including the removal of unsuitable ground and backfilling with suitable material, shall
be measured and paid for under Division 4200.
Payment shall distinguish between trimming in soft (normal) material and trimming in hard (rock or
boulder) material as defined in Clause 4204.
No extra payment shall be made in respect of any soil or gravel backfilling, additional concrete or
mass-concrete backfilling required on account of over-break or unavoidable unevenness of the
excavations in difficult ground, the cost of which shall be deemed to be included in the tendered rates
for trimming in hard material.
Item 33.08 Selected backfill material under concrete-lined side drains compacted to 93% of
modified AASHTO density ............................................................. cubic metre (m³)
The unit of measurement shall be a cubic metre of compacted material and the quantity shall be
calculated from the authorised dimensions given on the drawings.
The tendered rate shall include full compensation for procuring, as if from soft excavation or borrow
pits; breaking down, placing and compacting the material in 150mm layers; transporting; and for
shaping the top surface in accordance with the Drawings.
Item 33.09 Concrete lining for open drains

a) Cast in-situ concrete lining (concrete and type of open drain indicated) ......... cubic metre (m³)
b) Class U2 surface finish to cast in-situ concrete (type of open drain indicated) .........................
...................................................................................................................... square metre (m²)
The unit of measurement for cast in-situ concrete lining shall be the cubic metre of concrete and shall
be the square metre of finished surface.
Measurement and payment under this item shall be for concrete and surface finish as specified in
Divisions 8400 and 8200 respectively. The tendered rate shall include full compensation for painting
open joint surfaces as specified.
The tendered rates shall also include full compensation for all labour, plant, material and other
additional works and incidentals required for the concrete lining as specified.
Item 33.10 Formwork to cast in- situ concrete lining for open drains (class F2 surface finish)
a) To sides with formwork on the internal face only ........................................... square metre (m²)
b) To sides with formwork on both internal and external faces (each face measured) ..................
....................................................................................................................... square metre (m²)
c) To ends of slabs ............................................................................................. square metre (m²)
Measurement and payment for formwork under this item shall be as specified in Division 8200.
Formwork under item 33.10(a) shall be measured and paid only when the side slope of the slabs
exceeds 1 in 2 and the slabs cannot be constructed without formwork even when a stiff concrete mix is
used. When the contractor elects to use precast side slabs, payment will be made for formwork as if
cast in- situ concrete had been used.

Item 33.11 Sealed joints in concrete linings of open drains (description of type with
reference to drawing) ....................................................................... linear metre (m)
The unit of measurement shall be the linear metre of completed joint of each size and type.
The tendered rate shall include full compensation for the supply of all materials and for all labour,
formwork and incidentals necessary for sealing the joint as shown on the Drawings or specified in the
particular specifications.
Item 33.12 Concrete screed or backfill below chutes (class of concrete indicated)
........................................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of concrete screed or backfill as may be instructed
by the Engineer to be placed below chutes.
The tendered rate shall include full compensation for furnishing, procuring and placing the concrete in
screed or backfill.
Item 33.13 Steel reinforcement

a) Mild steel bars (grade specified) ....................................................................................tonne (t)
b) High-tensile steel bars (grade specified) .......................................................................tonne (t)
c) Welded steel fabric ........................................................................................... kilogramme (kg)
Measurement and payment under this item shall be for steel reinforcement in accordance with the
provisions of Division 8300.
Item 33.14 Polyethylene sheeting for concrete-lined open drains ............. square metre (m²)
The unit of measurement shall be the square metre of area covered with polyethylene sheeting as
specified on the Drawings.
The tendered rate shall include full compensation for procuring, furnishing and installing the
polyethylene sheeting, including wastage and overlap.
Item 33.15 Cutting bituminous surfacing and pavement layers for concrete kerbing,
channeling or concrete-lined drains .............................................. linear metre (m)
The unit of measurement shall be the linear metre of bituminous surfacing and pavement layers cut
where instructed by the Engineer, irrespective of the depth of cut. The various layers shall not be
measured separately for payment.
The tendered rate shall include full compensation for all labour, construction plant and materials
required for cutting the surfacing and pavement layers to the required depth, removing and disposing
of the debris, and protecting and keeping the surfacing clean, all as specified.
Item 33.16 Pre-cast concrete blocks in outlet structures (size specified) .......... number (No)
The unit of measurement is the number and size of precast concrete blocks provided and installed as
shown on the Drawings or directed by the Engineer.
The tendered rate shall include full compensation for procuring, transporting and placing the pre-cast
concrete blocks as shown on the Drawings or as instructed by the Engineer; including any labour,
materials and other incidentals and additional work required to complete the operation to the
satisfaction of the Engineer.

Item 33.17 Paved Drains in Urban Areas and Reinforced Drain Covers
a) U-shaped drains in urban areas (as per Drawings)
(i) Stone Masonry (structure, type, size and dimensions indicated). .. linear metre (m)
(ii) Concrete (structure, type, size and dimensions indicated) ............. linear metre (m)
b) Reinforced Concrete Drain Covers (as per Drawings)
(i) Pedestrian crossing covers (type, size and dimensions indicated) .... number (No)
(ii) Vehicle crossing covers (type, size and dimensions indicated) .......... number (No)
The unit of measurement for U-shape drains either in stone masonry or concrete shall be the metre.
The unit of measurement for reinforced concrete drain covers for pedestrian and vehicle crossings
shall be the number of covers.
The tendered rate shall include full compensation for all concrete or stone masonry works; supply of all
materials and placing of reinforcement mesh and formwork; including all labour, plant, plant and other
incidentals and additional work required for trimming the concrete lining as specified.
Item 33.18 Stone masonry paved ditch in rolling and other terrain as per Drawings
(structure, type, size and dimensions indicated) .......................... linear metre (m)
The unit of measurement for stone masonry paved ditches in rolling and other terrain shall be the
metre.
The tendered rate shall include full compensation for stone masonry with a mortar ratio of 1:3,
constructed in rolling and/or mountainous sections with trapezoidal shape as shown on the Drawings
or as instructed by the Engineer. The rate shall include 25mm thick masonry; the mortar as indicated;
and removal, shaping and trimming of the existing ground to the specified dimensions.

Division 3400: Stone Pitching, Masonry, Precast Concrete Block

and Riprap
3401 Scope
This Division covers the furnishing of materials and construction of erosion protection in stone pitching
(dry and grouted), masonry, precast concrete block paving, or heavier protection in the form of riprap
as shown on the Drawings, or as ordered by the Engineer.
3402 Materials
(a) Stone
(i) Pitching and Masonry

Stone for pitching and masonry shall be sound, tough and durable with no stone less than 200mm in
minimum dimension; except that smaller pieces or spalls may be used for filling spaces between the
larger stones. Rocks or stone shall be of such a shape as to form a stable protection structure of the
required section. Rounded boulders or cobbles shall not be used on slopes steeper than 2:1 grade
unless grouted.
All stone intended for use on any particular pitching works shall receive the prior approval of the
Engineer.
(ii) Riprap
Stone for riprap shall be hard field or quarry stone not susceptible to disintegration or excessive
weathering on exposure to the atmosphere or water. It shall be free from soft material such as sand,
clay, shale or organic material and shall not contain an excessive amount of elongated or flakey stone.
The required size of stone shall be determined by the "critical mass" specified. At least 50% by mass
of the material comprising the riprap shall consist of stones having a mass heavier than the critical
mass and not more than 10% by mass of the material shall consist of stone having a mass of less than
10% of the critical mass or more than 5 times the critical mass.
The grading requirements for riprap are shown in Table 3402/1.
(b) Cement
Cement shall be Ordinary Portland Cement complying with the requirements of BS 12 Part 2 or
Type II, AASHTO M 85.
(c) Sand
(i) Sand for Cement Mortar

Sand for the cement mortar shall comply with the requirements of BS 882.
(ii) Sand for Bedding

Sand for bedding used for stone pitching shall not contain any deleterious impurities and shall comply
with the grading requirements in Table 3402/2.
(iii) Sand for Joints

Sand used for brushing into joints between pavement blocks shall all pass the 1.18mm sieve; and
between 10 and 15% shall pass the 0.075mm sieve.

Table 3402/1: Gradation Requirements for Riprap
Mean Critical Approximate

Mass
Class Diameter Mass Rock By Mass (%) Cubic
(Kg)
(D50) (Kg) Dimension (mm)
20 10 – 15 150 – 200
30 5 – 10 125 – 150
1 125 5
40 0.5 – 5 50 – 125
10 0 – 0.5 0 – 50
20 25 – 50 200 – 250
30 10 – 25 150 – 200
2 175 10
40 1 – 10 75 – 150
10 0–1 0 – 75
20 100 – 150 350 – 400
30 50 – 100 250 – 350
3 300 50
40 5 – 50 125 – 250
10 0–5 0 – 125
20 250 – 350 450 – 500
30 100 – 250 350 – 450
4 400 100
40 10 – 100 150 – 350
10 0 – 10 0 – 150
20 700 – 1 000 650 – 700
30 350 – 700 500 – 650
5 500 350
40 25 – 350 200 – 500
10 0 – 25 0 – 200
20 850 – 1 600 700 – 850
30 500 – 850 550 – 700
6 600 500
40 50 – 500 250 – 550
10 0 – 50 0 – 250
Table 3402/2: Sand for Bedding
Sieve size (mm) % Passing

9.52 100
4.75 95 -100
2.36 80 - 100
1.18 50 - 85
0.600 25 - 60
0.300 30 - 10
0.150 5 - 15
0.075 50 - 10
(d) Precast Concrete Blocks

Interlocking concrete blocks shall be factory produced precast blocks manufactured from concrete
having a 28-day crushing strength of not less than 20 MPa. The design shall be subject to the
Engineer's approval and must ensure a sound interlock between adjacent blocks. The thickness shall
be as indicated on the Drawings and the blocks shall be manufactured to a tolerance of 3mm in any
dimension.
Square precast concrete blocks for footways shall, unless otherwise specified, measure 450 x 450 x
50mm and shall be manufactured from Class C 20/20 concrete. The requirements for appearance
shall be as specified in BS 368. The upper surface of the concrete block shall have an approved skid
resistant pattern.
(e) Concrete
All concrete work shall be carried out in accordance with the provisions of Division 8400.

(f) Wire
Wire for wired pitching shall consist of 4mm diameter galvanized wire complying with the requirements
of BS 183.
(g) Permeable Material for Filter Layers

Permeable material for filter layers shall comply with the requirements specified for permeable material
for subsurface drains in Clause 3107.
(h) Synthetic Fibre Filter Fabric (Geotextiles)

Synthetic fibre filter fabric shall be of the grade and type specified in the Bill of Quantities or Particular
Specifications, and shall comply with the requirements of Clause 3107(a)(iii).
3403 Construction Requirements for Stone Pitching
(a) Dry Stone Pitching

The area shall be prepared by excavation, shaping and trimming to accommodate the stone work and
shall be thoroughly compacted by hand-ramming to minimise subsequent settlement. A trench shall
be excavated along the toe of any slope to be pitched or along the unprotected edge of the pitching in
the beds of streams.
(i) Method 1
Commencing at the bottom of the trench, the stone shall be laid and firmly bedded into the prepared
surface and against adjoining stones. The stones shall be laid with their longest axes at right angles to
the prepared surface. The stone shall be in contact with the adjacent stone and be set so as to break
joints. The stones shall be well-rammed into the bank or surface to be protected and the spaces
between the larger stones shall be filled with fragments of approved pitching stone securely rammed
into place.
Placing of rock by dumping shall not be allowed.
(ii) Method 2
The technique and requirements laid down in method 1 shall also apply to method 2, except in the
following aspects:
 No small stones or spalls shall be used to fill in spaces between larger stones.
 Simultaneously with the placing of stones, topsoil shall be introduced between individual
stones, and sufficiently rammed so as to provide a firm bonded structure. The topsoil shall be
provided to the full depth of the stone pitching at any point.
 Rooted grass or tufts of grass shall be planted in the topsoil between stones and copiously
watered immediately; and at regular intervals thereafter until the grass has been established.
(iii) Finished Surface Tolerances

Whichever of the two methods is adopted, the finished surface of the pitching shall present an even,
tight and neat appearance with no stones varying by more than 50mm from the specified surface
grades or lines. The thickness of the pitching, measured at right angles to the surface, shall be not
less than 200mm.
(b) Grouted Stone Pitching

Grouted stone pitching shall be Class B in accordance with Clause 8903 (b), except that the spaces
between the stones shall be filled with cement mortar composed of one (1) part of cement to three (3)
parts of sand. Before the mortar is applied, the adjacent surfaces of the stones shall be thoroughly
cleaned of adhering dirt and clay, and then moistened.

The mortar shall be placed in a continuous operation for any day's run at any one location. The mortar
shall be worked into the pitching so as to ensure that all spaces or voids between the stones are
completely filled with mortar; and to the depth of the stone pitching.
After the grout has been placed, the stones shall be thoroughly brushed so that their top surfaces are
exposed. The grouted pitching shall be cured for a period of not less than four (4) days after grouting
with wet sacking or other approved wet cover; and shall not be subjected to loading until adequate
strength has been developed. Where required, weep-holes shall be formed in the pitching.
(c) Wired and Grouted Stone Pitching

The pitching shall be held in position below and above with wire nets of 150mm square mesh. The
lower net with wire ties fastened to it at 600mm centres and projecting outwards shall first be placed
over the surface to be pitched. The stone shall then be laid on the net in accordance with the
requirements specified for dry stone pitching in Sub-clause 3403(a).
After the stone has been laid, the upper wire net shall be drawn tightly over the stone course and
securely fastened down by means of the wire ties passing from the lower net through the pitching.
After tying, these ties shall be turned down into the pitching. The whole area of wired pitching shall
then be grouted and finished with cement mortar in accordance with the requirements specified for
grouted stone pitching in Sub-clause 3403(b).
(d) Grouted Stone Pitching on a Concrete Bed

The area to be pitched shall be prepared as described in Sub-clause 3403(a) and a concrete bed in
accordance with the provisions of Division 8400 with a thickness of at least 75mm shall then be
placed.
The stone pitching shall be of stones with a minimum dimension of 200mm, which shall be laid while
the concrete is still fresh. Openings between stones shall be filled with cement grout as described in
Sub-clause 3403(b); and care shall be taken not to spill the grout onto the exposed surfaces of the
stones. Grout spilt on to the exposed surfaces of the stones shall be removed while still wet and the
joints between stones shall be neatly finished.
Curing shall be as described for grouted stone pitching in Sub-clause 3403(b).
The completed pitching shall have an even compacted appearance, and nowhere may the surface
deviate by more than 25mm from the specified lines and grades.
3404 Riprap
(a) General
Riprap shall consist of a course(s) of large rock placed on bank slopes and toes; river and
streambeds; and other localities where protection of this type may be required. Stone for riprap shall
conform to Sub-clause 3402(a)(ii).
Two types of riprap are specified:
 Packed riprap: where the rocks are individually packed;

 Dumped riprap: where the stone is dumped and then spread by machines.
The surface of the areas to receive riprap shall be neatly trimmed to line and level and all loose
material compacted. The perimeters of riprap shall be protected by the construction of either
rock-filled trenches, walls, or other structures as may be required. Perimeter trenches shall normally

be backfilled with rock of the same size and quality as used in the construction of the riprap it adjoins.
Any cavities shall be filled with smaller material and the whole backfill shall be well consolidated.
(b) Filter Bed

The filter bed shall consist of a layer(s) of permeable material placed on the prepared surface to the
required thickness and finished to an even surface and thickness after placing each layer. Compaction
of previous material will not be required. Care shall be taken neither to mix various grades of filter
materials nor to disturb material already placed when constructing subsequent layers or riprap.
When the use of synthetic fibre filter fabric is required the material shall be placed on the prepared
surface, or on the filter backing as may be required. The overlap between adjacent sheets shall be
150mm unless otherwise specified. Care shall be taken not to damage the filter fabric when placing
subsequent layers; nor to expose the filter fabric when placing subsequent layers; nor to expose the
filter fabric to the sun for periods of more than a day before covering.
(c) Packed Riprap

Packed riprap shall be constructed from rocks individually placed to break joints and firmly bedded on
the prepared surface. The spaces between larger stones shall be filled with spall and smaller stones
securely rammed into place. On inclined surfaces the rock shall be laid in long horizontal lengths
starting from the bottom and not in strips up the slope. The completed riprap shall present an even,
tight surface. Local surface irregularities of the riprap shall not exceed 150mm.
(d) Dumped Riprap

Dumped riprap shall be constructed by dumping the stone on the prepared surfaces, spreading it with
a bulldozer, or other suitable earthmoving equipment, and trimming to the required lines and levels.
The material shall be placed in a manner that shall prevent segregation of the small and larger stones.
The final layer shall be tight with a minimum of voids.
3405 Stone Masonry Walls
(a) General
Stone masonry walls shall be plain with dry joints or constructed with stones set in cement mortar as
indicated on the Drawings or as instructed by the Engineer.
The minimum mass of stone shall be 10kg. The minimum dimension of stone shall be 75mm.
(b) Dry Stone Masonry Walls

A foundation trench shall be excavated down to rock, or to material of adequate bearing capacity at a
minimum depth of 300mm below ground level. All large stones shall be laid with the longest dimension
in the horizontal plane. Stones shall be individually placed to break joints, to provide a minimum of
voids, and shall be firmly bedded against adjoining stones. The spaces between the larger stones
shall be filled with spall securely rammed into place. The larger stones shall not bear on the spall used
to fill the voids. The top and ends of the wall shall be neatly finished with selected coping stones laid
with their largest dimension in the horizontal plane.
The finished surface of the wall shall present an even, tight and neat appearance with no stones
varying by more than 50mm from the specified surface grade or line.
All stones shall be carefully set with a bond stone provided at the rate of not less than one (1) to every
square metre of exposed face. Bond stones shall measure not less than 150mm by 150mm on the
exposed face and not less than 450mm in length; or the full thickness of the wall if the latter is less
than 450mm.

(c) Cement Mortared Stone Masonry Walls

The walling shall be constructed as specified in 3405(b), with the exception that the stones shall be
wetted and set in 3:1 sand/cement mortar. All large stones shall be laid with the longest dimension in
the horizontal plane. Exposed stones on the wall faces shall be cleaned of mortar by washing or wire
brushing. The mortar shall be flush-pointed to the approval of the Engineer.
Weep holes shall be provided as ordered and shall be cleaned of mortar and any other debris or
obstruction that may have entered during construction.
The walling shall be protected from the elements and kept moist for a minimum period of four (4) days
after completion.
3406 Concrete Block Pitching
(a) General
The underlying layers for surfaces to be pitched shall be constructed as specified or as indicated on
the Drawings. Where no specified requirements have been set in respect of the underlying layers, the
top layer shall be mechanically compacted to at least 90% of modified AASHTO density down to at
least 150mm from the top. During this process the top layer shall be trimmed to the required grades
and levels.
Where specified or required by the Engineer the prepared surface shall be treated with an approved
environmentally friendly herbicide and ant/termite poison before the layer of sand for bedding is
placed.
Where required a layer of sand for bedding shall be placed on top of the prepared surface, and, when
still loose, accurately floated to an uncompacted thickness of 30mm (± 5mm) so as to afford the
correct level to the pavement after compaction. Sand for bedding shall be placed immediately before
the paving blocks are laid and shall not be compacted before the blocks have been laid.
The pattern for laying the paving blocks shall be that as shown on the Drawings or as instructed by the
Engineer. Unbroken blocks shall first be laid and filler pieces added afterwards. Filler pieces shall be
neatly sawn or hewn to fit exactly into the space to be filled.
Spaces of less than 25% of a full-sized block may be filled with concrete Class C 25/20. The joints
between blocks shall be sized between 2 and 6mm, and the top faces of blocks shall be flush. After
the paving blocks have been laid, and where required, the pavement shall be compacted by a
vibrating-plate compactor. After compaction of the pavement, joint sand shall be spread and brushed
into the joints until the joints have been properly filled. Any surplus sand shall then be broomed off,
and where required, the pavement shall then be subjected to two further passes of the plate vibrator.
(b) Interlocking Type Concrete Blocks

On surfaces paved for pedestrian or cycle traffic, a 50mm layer of sand shall first be spread and
levelled on the surfaces to be paved. When required the prepared surfaces shall be treated with an
approved environmentally friendly herbicide and ant/termite poison in accordance with the Engineer's
instructions. The concrete blocks shall then be laid up against each other with each block interlocking
with the previously laid blocks.
At edges, special edge blocks shall be placed or the edges shall be finished by means of concrete
edge beams to the dimensions shown on the Drawings. Concrete shall be Class C 20/20 concrete.
Earth cuts may be used as forms for the vertical surfaces of edge beams if such cuts are suitable.

Where formed vertical faces are used they shall be Class F2 finish. The upper surface shall be Class
U2 surface finish as specified in Division 8200.
The finished surface of the pitching shall present an even and neat appearance with no concrete
blocks projecting above the surface. The pitching shall not vary by more than 15mm from the specified
lines and grades.
(c) Precast Concrete Blocks for Footway Pavements

The areas shall be prepared as specified for interlocking type concrete blocks in Sub-clause 3406(b),
including a 50mm sand bed. Where required the joints shall be grouted with 3:1 sand/cement mortar.
The finished surface shall vary by not more than 10mm from the specified surface lines and grades
and shall be flush with any kerbing at the edges.
3407 Cast In-Situ Concrete Pitching

The areas where cast in-situ concrete pitching is to be constructed, shall be compacted, trimmed and
prepared as described in Clause 3406 for concrete block pitching. The areas shall also be treated with
an approved environmentally friendly herbicide and ant/termite poison if required.
Prior to the placing of concrete the surface shall be watered and kept damp until the concrete is
placed. Concrete Class C 25/20 shall be accurately laid in alternate panels to the lines and levels
indicated. Accurate screeds shall be set to achieve the required line and slope. The concrete shall be
thoroughly compacted and finished to a Class U2 surface finish as specified in Division 8200.
Where indicated the concrete pitching shall be contained by the construction of concrete edge beams
constructed as described in Sub-clause 3406(b) for interlocking type concrete blocks.
The concrete pitching shall be cured for at least seven days and no traffic shall be allowed to move
across the pitching before the specified 28-day strength has been reached.
The final surface shall not deviate by more than 25mm from the specified levels and planes, and no
irregularities exceeding 10mm shall occur during testing with a 3m straight-edge.

Item 34.01 Stone Pitching

a) Plain (dry stone) pitching
2
(i) Method 1 ...................................................................................... square metre (m )
2
(ii) Method 2 ...................................................................................... square metre (m )
b) Grouted pitching ............................................................................................ square metre (m²)
c) Wired and grouted pitching ............................................................................ square metre (m²)
The unit of measurement for pitching shall be the square metre of each type of pitching in place.
The tendered rate for each type of stone pitching shall include full compensation for furnishing all
materials; excavations (excluding trench and bulk excavations); compaction and trimming of the
excavated areas; forming and cleaning of weep holes; placing of stones; grouting where applicable;
and for all other work necessary to complete the pitching as specified.
The tendered rate for grouted stone pitching on a concrete bed shall also include full compensation for
the concrete bed.

Excavations for foundation trenches and edge beams and the construction of edge beams will be paid
for separately.
Item 34.02 Riprap

a) Packed riprap (class indicated) ........................................................................ cubic metre (m³)
b) Dumped riprap (class indicated) ...................................................................... cubic metre (m³)
c) Filter layer
3
(i) Crushed stone ............................................................................... cubic metre (m )
3
(ii) Filter sand obtained from borrow pits ............................................ cubic metre (m )
d) Synthetic fibre filter fabric (type class and grade stated) ............................... square metre (m²)
The unit of measurement for riprap, sub-items (a), (b) and (c) shall be the cubic metre of riprap in
place including rock in trench backfill. The unit of measurement for sub-item (d) shall be the square
metre of filter fabric laid as specified including overlaps.
The rates tendered for sub items (a), (b) and (c) shall include full compensation for the preparation of
surfaces, including excavations, (but excluding excavations for trenches and bulk excavations), and for
the furnishing, transporting, handling, and placing of riprap.
The rate tendered for sub-item (d) shall include full compensation for procuring and furnishing the filter
fabric and for laying it as specified, including wastage.
Collectively the rates shall also include full compensation for all other incidentals necessary for
completing the work as specified.
Item 34.03 Stone masonry walls

a) Dry stone masonry walls .................................................................................. cubic metre (m³)
b) Cement-mortared stone walls .......................................................................... cubic metre (m³)
The unit of measurement for stone masonry walls shall be the cubic metre of actual walling
constructed and accepted.
The tendered rate for each type shall include full compensation for furnishing all materials; trimming of
areas; placing of stones and cement-mortar where necessary; and all other work necessary to
complete the walls as specified. Excavation of foundation trenches will be paid separately.
Item 34.04 Concrete pitching

a) Cast in-situ concrete pitching (class of concrete and thickness of pitching indicated) ...............
....................................................................................................................... square metre (m²)
b) Interlocking pre-cast concrete block pitching (type and thickness indicated) .............................
....................................................................................................................... square metre (m²)
c) Pre-cast concrete blocks for side walk pavement (thickness indicated) ....................................
2
...................................................................................................................... square metre (m )
The unit of measurement shall be the square metre of each type constructed.
The tendered rates shall include full compensation for furnishing all materials; all excavations (but
excluding bulk excavation and excavation for foundation trenches and edge beams); compacting and
trimming of all excavated areas; provisions of sand bedding (sub-items (b) and (c)); treatment of the

prepared area with an approved environmentally-friendly herbicide/pesticide as instructed by the

Engineer; and for all other work necessary for completion as specified.
Item 34.05 Concrete in edge beams and foundation trenches (Class of concrete indicated)
.......................................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of concrete in edge beams and foundation trenches
constructed as instructed.
The tendered rates shall include full compensation for furnishing all materials and labour, including
formwork as necessary, for placing concrete and shaping all surfaces.
Item 34.06 Excavations for edge beams and foundation trenches

a) In solid rock (material requiring blasting) ..........................................................cubic metre (m³)
b) In all other classes of material ..........................................................................cubic metre (m³)
The unit of measurement in each class of material shall be the cubic metre of excavation made in
accordance with the authorised dimensions.
The tendered rates shall include full compensation for excavation in each class of material including
for over-break and any additional concrete necessitated by over-break; for trimming of trenches and
compaction of the trench inverts; and for the transport and disposal of surplus excavated material to
spoil.

Division 3500: Drainage Structure Protection
3501 Scope
This Division covers the material and construction requirements for various options of bridge abutment
and culvert protection as shown on the Drawings or ordered by the Engineer.
3502 Protection Type 1 – Rock Spill Through
(a) Material Requirements

Rock employed for protection shall be as specified in the Drawings or, if not so shown, rock used shall
be of a size not less than 150mm and not greater than 500mm. Rock shall be well graded with not
less than 50% larger than a size twice the minimum size specified.
Rock shall be clean, hard, dense and durable. In addition, it shall be resistant to weathering, free from
overburden, spoil, shale and organic matter. Rock that is laminated, fractured, porous, or otherwise
physically weak shall not be used. The breadth or thickness of a single stone shall be not less than
one-third (⅓) of its length.
Cement mortar shall consist of 1:3 cement/sand mixture with sufficient water added to achieve a
plastic-like texture. Hydrated lime may be incorporated into the cement mortar to the extent of 1:10
hydrated lime/cement. Hydrated lime shall be an addition to, and not a replacement for the cement.
The mortar shall be able to retain its shape and not be in a liquid form.
(b) Construction
Rock spill through protection shall be constructed in the locations and in accordance with the
Drawings. The toe-wall shall be constructed to the width and depth shown on the Drawings.
Rock spill-through material shall be placed in a manner which ensures that the larger rocks are
uniformly distributed throughout the spill-through zone, and that the smaller rocks effectively fill the
spaces between the large rocks without leaving any large voids. The layers of placed rock shall be of
even thickness and of even grading.
The placing operations shall minimise the chances of rock running loose and damaging adjacent
areas. Rock deposited in areas outside the rock spill-through zone shall be recovered. In addition,
the face of rock spill-through shall be hand-packed with selected smaller rock and grouted with cement
mortar to give a relatively smooth and even appearance. Excess mortar shall be removed from the
rock faces before it hardens.
3503 Protection Type 2 – Reinforced Concrete over Earth Spill-through

Welded steel wire reinforcing fabric shall be as shown on the Drawings. Compressible packing shall
be 10mm thick bitumen impregnated fibre board or other suitable packing.
Reinforced concrete shall be supplied in accordance with the Specifications in Divisions 8300 and
8400 of Series 8000.
(b) Construction
Reinforced concrete protection shall be constructed in the locations and in accordance with the
Drawings. Embankment faces shall be slightly overfilled during embankment construction and trimmed

to the correct profile prior to placing the reinforced concrete protection. Cut faces shall be trimmed
neatly to the lines specified on the Drawings. The trimmed faces shall be lightly compacted. The
embankment face shall be true to line such that the deviation of the ground surface from a 3m
straightedge held in any direction does not exceed 25mm.
The toe-wall shall be constructed to the width and depth specified on the Drawings and shall be
reinforced with welded steel wire reinforcing fabric.
The embankment face shall be boxed, where required and as instructed by the Engineer. If no boxing
is used, screed boards or level pins shall be installed to ensure an accurate surface profile and to
maintain the depth of concrete specified on the Drawings. Level pins shall be hot-dipped galvanised
12mm diameter steel reinforcing bars of sufficient length to be accurately located by driving into the
embankment face. Welded steel wire reinforcing fabric shall be placed with a minimum cover of
75mm from the embankment face.
Where a slab is more than 12m wide on the plane face (not including curved faces at the edges),
vertical expansion joints shall be formed at 6m to 9m centres. Reinforcement shall not be continuous
through these joints. Where the face of a curved embankment is formed in a series of straights,
contraction joints shall be formed at the junction between the adjacent straight segments of concrete
slab.
Expansion joints shall be formed to full depth using compressible packing. Contraction joints shall be
constructed by forming grooves 40mm deep and not more than 6mm wide in the surface of the slab.
(c) Tolerances
The tolerances of the finished surface shall be such that the gap beneath a 3m straight-edge placed
anywhere on the finished surface shall not exceed 25mm. Due allowance shall be made for the
design shape, where relevant.
3504 Protection Type 3 – Rockwork over Earth Spill-Through

Rock shall be sound igneous or metamorphic rock that shall not be susceptible to excessive
weathering and disintegration when exposed to water. Rock shall be free from overburden, spoil,
shale and organic matter. Rock that is laminated, fractured, porous, or otherwise physically weak shall
not be used. Rock shall be of a size not less than 200mm and the least dimension of any rock shall be
not less than half its greatest dimension.
Cement mortar shall consist of 1:3 cement/sand mixture with sufficient water added to achieve a
plastic-like texture. Hydrated lime may be incorporated into the cement mortar to the extent of 1:10
hydrated lime/cement. Hydrated lime shall be an addition to, and not a replacement for the cement.
The mortar shall be able to retain its shape and not be in a liquid form.
(b) Construction
Rockwork protection shall be constructed in the locations and in accordance with the Drawings. Rock
material shall be placed in a manner which ensures that the larger rocks are uniformly distributed
throughout the rockwork layer and that the smaller rocks effectively fill the spaces between the large
rocks without leaving any large voids. The layers of placed rock shall be of even thickness and of
even grading.
The placing operations shall minimise the chances of rock running loose and damaging adjacent
areas. Rock deposited in areas outside the rock spill-through zone shall be recovered. In addition,
the face of rock spill-through shall be hand-packed with selected smaller rock and grouted with cement

mortar to give a relatively smooth and even appearance. Excess mortar shall be removed from the
rock faces before it hardens.
3505 Protection Type 4 – Interlocking Blockwork over Earth Spill-through

Blocks shall be interlocking blocks manufactured from concrete with nominal dimensions of:
 610mm x 150mm x 115 mm thick;

 440mm x 500mm x 100mm thick.
The concrete strength shall be a minimum of 25kN at 28 days. The minimum mass of the interlocking
2
block shall be 170kg/m .
(b) Construction
Interlocking blockwork protection shall be constructed in the locations and in accordance with the
Drawings. Embankment faces shall be slightly overfilled during embankment construction and
trimmed to the correct profile prior to laying the interlocking blockwork protection. Cut faces shall be
trimmed neatly to the lines specified in the Drawings. The trimmed face shall be lightly compacted.
The embankment face shall be true to line such that the deviation of the ground surface from a 3m
straight-edge held in any direction does not exceed 25mm. Faces of curved embankments shall be
either a smooth curve or formed in a series of straights of approximately equal size. Curved faces of
embankment shall conform to the 25mm deviation when a 3m straight-edge is placed in a vertical
direction up the sloping face, and shall form a smooth curve in the horizontal direction.
(c) Tolerances
The tolerances of the finished surface shall be such that the gap beneath a 3m straight-edge placed
anywhere on the finished surface shall not exceed 25mm with due allowance being made for the
design shape, where relevant.
3506 Weepholes
All walls and abutments shall be provided with weepholes. Unless otherwise shown on the Drawings
or directed by the Engineer, the weepholes shall be placed horizontally at the lowest point where free
outlets for water can be obtained and shall be spaced at not more than 2m centres in a staggered
manner. The length of weepholes shall not be less than the thickness of the wall of the abutment and
shall be at least 50mm diameter PVC or other pipe materials approved by the Engineer. Weepholes
must be provided with synthetic filter fibre fabric as shown on the Drawings, specified in the Particular
Specifications or as directed by the Engineer.


Item 35.01 Drainage Structure Protection

a) Protection type 1 – rock spill through ........................................................... square metre (m²)
b) Protection type 2 – reinforced concrete over earth spill-through .................. square metre (m²)
c) Protection type 3 – rockwork over earth spill-through .................................. square metre (m²)
d) Protection type 4 – interlocking blockwork over earth spill-through ............. square metre (m²)
The unit of measurement for drainage structure protection shall be the square metre of each type of
protection in place.
The tendered rate for each type of protection shall include full compensation for furnishing all
materials; excavations (excluding trench and bulk excavations); compaction and trimming of
excavated areas; forming and cleaning of weep holes; placing of rocks; grouting where applicable; and
all other work necessary to complete the type of protection as specified. No separate payment shall be
made for weepholes.
All concrete and reinforcement under this item shall be as specified in Divisions 8300 and 8400.

Series 4000: Earthworks and Material Stabilisation
TABLE OF CONTENTS
DIVISION 4100: PREPARATION OF ROADBED .......................................................................................... 226
4101 General ..................................................................................................................................... 226
(a) Scope .............................................................................................................................................226
(b) Dimensions ....................................................................................................................................226
4102 Construction Requirements for the Preparation of the Roadbed.............................................. 226
(a) Equipment .....................................................................................................................................226
(b) Shaping and Compaction of the Roadbed on Suitable Material ....................................................226
4103 Treatment of the Existing Ground and of the Roadbed in Cuttings .......................................... 226
(a) Removal, Disposal and Replacement of Unsuitable Material ....................................................... 226
(b) Draining of Existing Ground and Roadbed ...................................................................................227
(c) In-Situ Treatment of Roadbed .......................................................................................................227
(d) Rock Sub-grade Preparation..........................................................................................................228
(e) Widening of the Roadbed ..............................................................................................................228
4104 Capping or Selected Layers ..................................................................................................... 229
4105 Protection of Earthworks ........................................................................................................... 229
4106 Problem Areas .......................................................................................................................... 229
DIVISION 4200: ROADWAY AND BORROW EXCAVATION ........................................................................... 232
4201 General ..................................................................................................................................... 232
(a) Scope .............................................................................................................................................232
(b) Dimensions ....................................................................................................................................232
4202 Topsoil ....................................................................................................................................... 232
4203 Borrow and Spoil ....................................................................................................................... 232
4204 Classes of Excavation............................................................................................................... 232
(a) Common (Normal or Soft) Excavation ......................................................................................... 232
(b) Rock (Hard) Excavation ................................................................................................................233
4205 Excavation of Unsuitable Material ............................................................................................ 233
4206 Method of Classifying ................................................................................................................ 233
4207 Construction Requirements for the Excavation of Cuttings ...................................................... 233

(a) Equipment ..................................................................................................................................... 233
(b) General .......................................................................................................................................... 233
(c) Dimension of Cuttings .................................................................................................................. 234
(d) Finish of Cut Slopes ...................................................................................................................... 234
4208 Use of Excavated Materials ...................................................................................................... 234
(a) Stockpiling of Material ................................................................................................................. 235
(b) Breaking down the Material .......................................................................................................... 235
(i) Initial Breakdown ..................................................................................................................................... 236
(ii) Further Breakdown for Fill ....................................................................................................................... 236
(iii) Further Breakdown for Pavement Layers ................................................................................................. 237
(c) Crushing and Screening ................................................................................................................ 237
(d) Control of Moisture Content ......................................................................................................... 238
(e) Disposal of Oversize and Surplus Excavated Soil or Rock ........................................................... 239
(a) General Directions ........................................................................................................................ 239
(i) Determining the Quantities ....................................................................................................................... 239
(ii) Material from Commercial Sources .......................................................................................................... 239
(iii) Work in Restricted Areas .......................................................................................................................... 240
DIVISION 4300: BORROW MATERIALS ................................................................................................... 243
4301 Scope ........................................................................................................................................ 243
4302 Obtaining Borrow Materials ...................................................................................................... 243
(a) Borrow Area Locations ................................................................................................................. 243
(b) Use of Borrow Materials ............................................................................................................... 243
4303 Opening and Working of Borrow Areas .................................................................................... 243
(a) Removal of Topsoil ....................................................................................................................... 243
(b) Clearing and Grubbing .................................................................................................................. 243
(c) Overburden ................................................................................................................................... 244
(d) Excavation of Borrow Material ..................................................................................................... 244
(e) Control at Borrow Areas ............................................................................................................... 244
(f) Protection of Borrow Area ............................................................................................................ 245
4304 Reinstatement of Borrow Areas ................................................................................................ 245
4305 Disposal of Borrow Material ...................................................................................................... 245
4306 Classification of Borrow Areas for Gravel Materials for Pavement Layers ............................... 245
4307 Establishing a Crushing Plant for Crushed Stone Base and Sub-base from Borrow Areas .... 245

DIVISION 4400: EMBANKMENT CONSTRUCTION ...................................................................................... 247
4401 General ..................................................................................................................................... 247
(a) Scope .............................................................................................................................................247
(b) Sources of Materials ...................................................................................................................... 247
4402 Material Requirements for the Construction of Embankments ................................................. 247
(a) Particle Size ...................................................................................................................................247
(b) California Bearing Ratio (CBR) ....................................................................................................247
(c) Liquid Limit (LL) and Plasticity Index (PI) ..................................................................................247
(d) Compaction ...................................................................................................................................247
4403 Construction Requirements for General Embankment Fills ..................................................... 248
(a) Layer Thickness ............................................................................................................................ 248
(b) Equipment .....................................................................................................................................248
(c) Spreading of Materials ..................................................................................................................249
(d) Oversize Material .......................................................................................................................... 249
(e) Placing and Compaction ................................................................................................................249
(f) Benching .......................................................................................................................................250
(g) Pioneer Layers ............................................................................................................................... 250
(h) Construction of Drainage Blankets ............................................................................................... 250
(i) Construction of High Embankments ............................................................................................. 250
(j) Sand Fill and Sand Filter Blankets ................................................................................................ 250
(k) Construction of Fills near Structures (excluding structural backfill) ............................................251
(l) Widening of Fills ........................................................................................................................... 251
(m) Finishing of Slopes ........................................................................................................................ 251
(n) Trial Areas .....................................................................................................................................252
4404 Rock Fill .................................................................................................................................... 252
(a) Constructing Toes for Rock Fill Embankments .............................................................................252
4405 Side Fill ..................................................................................................................................... 253
DIVISION 4500: M ATERIAL STABILISATION ............................................................................................. 256
4501 Scope ......................................................................................................................................... 256
4502 Materials.................................................................................................................................... 256
(a) Material to be Stabilised ................................................................................................................256
(i) Road Bed and/or Subgrade Stabilisation ................................................................................................... 256
(ii) Stabilised Sub-base and Road Base Material ............................................................................................ 256

(b) Stabilising Agents ......................................................................................................................... 256
(i) Ordinary Portland Cement ........................................................................................................................ 256
(ii) Portland Blast-Furnace Cement ................................................................................................................ 257
(iii) Lime .......................................................................................................................................................... 257
(iv) Other Chemical Stabilising Agents ........................................................................................................... 257
(v) Soil Binder ................................................................................................................................................ 257
(vi) Bituminous Stabilising Agents.................................................................................................................. 257
(vii) Fillers for Bitumen Stabilisation .................................................................................................... 257
(viii) Aggregate for Bitumen Stabilisation .............................................................................................. 257
(ix) General ..................................................................................................................................................... 257
4503 Chemical Stabilisation .............................................................................................................. 258
(a) Preparation of Layer ..................................................................................................................... 258
(b) Application of Stabilising Agent ................................................................................................... 258
(c) Mixing in of Stabilising Agent ...................................................................................................... 258
(d) Watering ........................................................................................................................................ 258
(e) Compaction ................................................................................................................................... 259
(f) Turning Areas and Joints with Completed Work ........................................................................... 259
(g) Curing of Stabilised Work ............................................................................................................. 259
(h) Construction Limitations............................................................................................................... 260
4504 Mechanical Modification ........................................................................................................... 260
(a) Modifying Soil and Gravel by the Addition of a Soil Binder........................................................ 261
(b) Mixing Materials from Various Sources ....................................................................................... 261
(c) Recombining Recovered Material................................................................................................. 261
4505 Bituminous Stabilisation ........................................................................................................... 261
(a) Preparing the Material ................................................................................................................... 261
(b) Mixing in of Active Filler ............................................................................................................. 261
(c) Heating and Diluting the Bituminous Stabilising Agent ............................................................... 262
(d) Applying the Stabilising Agent ..................................................................................................... 262
(e) Compaction ................................................................................................................................... 262
(f) Turning Areas and Joints with Completed Work ........................................................................... 263
(g) Construction Limitations............................................................................................................... 263
4506 Construction Tolerances ........................................................................................................... 263
(a) Rate of Application ....................................................................................................................... 263
(b) Uniformity of Mix ......................................................................................................................... 263
4507 Construction of Trial Section ..................................................................................................... 263

4508 Stabilisation Work in Restricted Areas ....................................................................................... 264
(a) General Requirements ...................................................................................................................264
(b) Chemical Stabilisation...................................................................................................................264
(c) Bituminous Stabilisation ...............................................................................................................264
4509 Quality Control .......................................................................................................................... 264
(a) Process Control ............................................................................................................................. 264
(i) Stabilising Agent ....................................................................................................................................... 264
(ii) Compaction ............................................................................................................................................... 265
(b) Routine Inspection and Testing .....................................................................................................265
(c) Defective Work or Materials .........................................................................................................265
4510 Other Stabilisers ....................................................................................................................... 265

List of Tables
Table 4404/1: Grading Requirements for Rock Fill ............................................................................. 252
Table 4503/1: Maximum time for completion in stabilisation ............................................................... 260

Division 4100: Preparation of Roadbed
4101 General
(a) Scope
This Division covers all work in connection with the preparation of the roadbed for cut and fill situation
and selected/capping layers prior to the construction of the pavement layers.
The Division also covers any capping or selected layers required to improve the roadbed to sub-grade
requirements as specified herein or as instructed by the Engineer.
(b) Dimensions
The dimensions shall be in accordance with the cross-sections and details shown in the Contract or as
4102 Construction Requirements for the Preparation of the Roadbed
(a) Equipment
Equipment used for the preparation of the roadbed; sub-grade in cuts and on level ground; and/or
capping/selected layers shall be suitable for use on the surface to be prepared.
The equipment shall not be less than that designated for that purpose in the Contractor’s programme
and plant list approved by the Engineer.
(b) Shaping and Compaction of the Roadbed on Suitable Material

The existing ground beneath embankments prior to their construction, existing level ground, or the
ground at the bottom of cuttings prior to construction of pavement layers shall have a density of not
less than 93% or 95% of the maximum dry density as required, determined in accordance with
AASHTO T-180.
In-situ material that is classified as suitable material but with a density of less than 93% or 95% of the
maximum dry density, as required, determined in accordance with AASHTO T-180, shall be scarified to
a minimum depth of 200mm that yields a minimum compacted layer thickness of 150mm, watered and
re-compacted to the specified density.
4103 Treatment of the Existing Ground and of the Roadbed in Cuttings

This Clause relates to the treatment of the following:
 Existing ground that will form the roadbed level for the construction of embankment fill after
clearing and grubbing;
 The top of the roadbed equivalent to the subgrade level reached after excavation for cuttings.
(a) Removal, Disposal and Replacement of Unsuitable Material

Any materials exposed in the preparation of the roadbed that are considered to be unsuitable by the
Engineer shall be removed to such widths and depths as ordered by the Engineer and disposed of as
directed. The volume of material removed shall be backfilled with approved imported material
compacted to the required density and level.

Unsuitable Material consists of:
 Peat and other organic materials from swamps, marshes and bogs that contain compressible
soils and excessive amounts of degradable organic matter such as decomposing wood and
other vegetation.
 Clay material having a Liquid Limit (LL) exceeding 60; or a Plasticity Index (PI) exceeding 30;
or CBR value less than 3% at 95% of modified AASHTO compaction (AASHTO method T-180)
after 4 days soaking; or a swell value of more than 3% (with two surcharge rings) when
determined in accordance with AASHTO T-193 at 95% of modified AASHTO compaction.
 Other problem soils such as expansive clays (also see Clause 4106); collapsible sands;
dispersive soils; saline soils; micaceous soils; and low strength soils. (Further information on
the identification and treatment of problem soils can be obtained from the prevailing version of
the ERA Design Manual for Low Volume Roads, the ERA Site Investigation Manual and the
ERA Geotechnical Design Manual for inclusion in Particular Specifications or as required by
the Engineer.)
 Any material that is sufficiently wet and soft to prevent it from being trafficked or excavated by
normal bulk earth-moving equipment.
The depth and width of excavations shall be as shown on the Drawings or as instructed by the
Engineer. The Engineer may ask the Contractor to drill boreholes or excavate pits to establish the
extent of the occurrence of unsuitable materials.
Excavated areas shall be backfilled with approved imported materials with the following properties:
 The CBR shall not be less than 5% at 95% of Modified AASHTO (T180) and where no capping
or selected layer is specified shall have a minimum soaked Californian Bearing Ratio (CBR) of
8% at 95% of Modified AASHTO (T180); and
 A swell value of not more than 2.0% (with two surcharge rings) when determined in
accordance with AASHTO T-193
Following excavation to the design sub-grade level, the Engineer may order the removal of additional
material that is too wet, expansive or generally unsuitable to a depth that shall provide a stable
platform for construction and/or the provision of adequate backfill for the construction of fills or the
pavement structure. In such circumstances, the Contractor shall be paid under Pay Item 41.01.
The removal of unsuitable materials, including expansive soils, that is undertaken as part of general
excavations to design levels shall be paid under Pay Item 42.03(a).
(b) Draining of Existing Ground and Roadbed

Any drainable waterlogged existing ground and/or roadbed, such as saturated material overlying less
pervious strata, shall first be drained by the installation of all permanent surface or subsoil drainage
shown on the Drawings or as directed by the Engineer, before any other construction is started on
these sections.
(c) In-Situ Treatment of Roadbed

Wherever shown on the Drawings or as directed by the Engineer, the roadbed shall be treated in-situ
by breaking up undesirable formations of hard or rocky materials in order to achieve a uniform
standard of subgrade compaction or to improve drainage.
Treatment in-situ shall consist of ripping or blasting the roadbed to depths, which, on normally
cambered sections (comprising a centreline crown), shall increase from the centre of the roadbed to
the edges. Unless otherwise indicated on the Drawings or directed by the Engineer, the depth of
ripping in the centre of the roadbed shall not be less than 300mm and at the edges of the roadbed not
less than 500mm. Similarly the depth of drilling (and blasting where required) shall not be less than
700mm at the centre of the roadbed, increasing outwards to not less than 1m at the edge of the
roadbed. On super-elevated sections the treatment shall, if so directed by the Engineer or shown on
the Drawings, have a uniform cross-fall and a minimum depth of 400mm in the case of ripping and
850mm in the case of blasting.
After ripping or blasting, the material shall be processed as follows:
 Where the Engineer instructs the Contractor to rip the in-situ material, the whole of the
material shall be sized by rolling or breaking until the maximum dimension of any clod or spall
is not more than two-thirds of the thickness of the layer after compaction. The maximum
thickness of the layer after compaction shall be 300mm.
 Where the Engineer instructs the Contractor to blast the in-situ material in line with the
requirements of Clause 1210, the whole of the material shall be processed as directed by the
Engineer. Maximum layer thickness after compaction shall be 500mm. Maximum dimension of
any material shall be 300mm. The material shall be systematically compacted by at least 8
passes of a vibratory roller with a static load of at least 36kN per 1m width of roll or a grid
roller with a static load of a least 80kN per 1m of roll width or other equipment approved on
site trials by the Engineer.
In both cases surplus material arising from bulking after treatment in place shall be removed and
disposed of, or utilised elsewhere, as directed by the Engineer.
(d) Rock Sub-grade Preparation

Rock sub-grade shall be prepared as follows:
 Remove all loose rock from the surface.

 Excavation in solid rock shall be minimum 150mm below the bottom level of the sub-base
unless otherwise agreed with the Engineer. Rock shall be undercut neatly to the required
elevation and sections shown on the Drawings or as directed by the Engineer. Any cuts made
below the sub-base level shall be backfilled with selected material of sub-base quality as
shown on the Drawings or as approved by the Engineer and compacted to a minimum 100%
of the maximum dry density as determined by AASHTO T-180 at the cost of the Contractor.
Performance of this work shall not be paid for under this Division but by the Contract prices for
relevant pay items.
 No rock shall be higher than two (2) centimetres above the undercut section elevation. The
excess cut material shall be placed in embankments or disposed of at the direction of
Engineer.
 All rock surfaces shall be prepared so that water cannot accumulate at any point. This shall be
achieved by constructing subgrade drains to connect depressions to the storm water system
or to longitudinal subsoil drains. Subgrade drains shall be at least 150mm wide and shall be
cleared of all earth and debris. All depressions and subgrade drains shall be backfilled with
course filter medium.
(e) Widening of the Roadbed

Where the road is to be widened, and where so instructed by the Engineer, the roadbed shall be
treated in accordance with the provisions herein. Where uncompacted roadbed material occurs below
the outer part of the fills, the fill material shall be cut back or cut away to expose the full width of the
roadbed widening to be treated.

4104 Capping or Selected Layers

Where shown on the Drawings or where instructed by the Engineer, a capping or selected layer(s)
shall be constructed over weak or poor quality sub-grade in cut or fill situations using material
complying with the requirements of Clause 4402 except that it shall have a minimum CBR of 7% for
lower capping layer and 15% for upper capping layers. The capping layer shall be constructed in
accordance with the requirements of Clause 4403.
Where any additional material has to be imported as a capping layer to achieve the required subgrade
strength and level, this material shall be placed and compacted to a minimum 93% or 95% of modified
AASHTO density as required in accordance with AASHTO T-180 and the layer thickness specified.
Where the specified layer thickness is less than the thickness required to achieve the specified
compacted density, strength and thickness (normally 150mm) then the underlying material shall be
scarified; the necessary imported material placed; and this combined material mixed and compacted
to the full specified depth of the layer to achieve the required level and density.
4105 Protection of Earthworks

This Clause covers all work in connection with the protection of earthworks (including, excavations,
embankments, slopes, roadbed and/or subgrade from the effects of weather.
Earthworks shall be protected from the weather at all times. The compacted layers of fill and the
bottom of excavations shall be adequately drained and shaped to prevent free water standing on or
scouring the completed layer(s) or the in-situ material. Any windrows or ridges which will impede the
free drainage of water shall be removed from the surface. No fill material for a succeeding layer shall
be placed if the underlying layer has been softened by excessive moisture.
All permanent drains, plus additional necessary temporary drains, shall be constructed as soon as
possible to protect the earthworks. Ruts, potholes and other damaged sections of earthworks and
slopes, shall be reinstated. Drains shall be constructed so as to avoid damage to embankments from
erosion.
Any runnels or erosion channels, which develop during the Contract period, shall be backfilled with
suitable materials, and the areas reinstated. The Contractor shall not allow erosion to develop on a
large scale before effecting repairs and all erosion damage shall be repaired as soon as possible.
4106 Problem Areas

The whole length of the road shall be investigated by the Contractor for problem soils as indicated in
sub-clause 4103(a). Should problem soils be found (and especially expansive soils with PI >30%, and
swell > 2.0%), the problem soil shall be excavated to the required depth as described herein and
replaced by a non-expansive material with CBR of 5-7% to the satisfaction of the Engineer. Further
details are provided in the ERA Low Volume Roads Design Manual for the classification of expansive
clays (Part D, Chapter 2, Section 2.5.2) and appropriate countermeasures based on the expansive
nature of the clay (Part D, Chapter 6, Section 6.19.2) and shall be included in the Particular
Specifications.
The following minimum treatment shall apply for low and medium expansive clays:
 Removal the of problem soil;

o Where the finished road level is designed to be less than 2 m above natural ground
level, remove the problem soil to a minimum depth of 600 mm over the full width of
the road

o Where the finished road level is designed to be greater than 2 m above natural ground
level, remove the problem soil to a depth of 600 mm below the ground level under the
unsurfaced area or shoulder of the road structure; or
o Where the expansive soil does not exceed 1m in depth, remove it to its full depth.
 Stockpile the excavated material on either side of the excavation for subsequent spreading on
the fill slopes so as to produce as flat a slope as possible (1V:6H).
 The excavated area shall be backfilled with a non-expansive material of CBR value greater or
equal to 5% and compacted to a density of 93% modified AASHTO.
 After the excavated material has been replaced with non-expansive material in 150mm lifts to
93% modified AASHTO density, the road shall be brought to finished level in approved
materials, with a side slope of 1:2 or as indicated on the Drawings. All other requirements for
pavement layers shall be complied with as specified. The previously stockpiled expansive soil
excavated as directed above should then be spread over the slope (side fill).

The construction of drainage systems for the existing ground and roadbed shall be measured and paid
for in accordance with the requirements of Division 3100.
Item 41.01 Removal of unsuitable material

a) In layer thicknesses of 200mm and less ........................................................ cubic metre (m³)
b) In layer thicknesses exceeding 200mm .......................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of unsuitable material removed and replaced by the
Contractor in accordance with the Engineer’s instructions and it shall be the in-situ volume of the
material calculated in accordance with its authorised dimensions.
The tendered rates shall include full compensation for the excavation of stable and unstable materials;
loading onto trucks and haulage to disposal areas; loosening and breaking up of materials before or
during excavation; multiple handling of excavated material; supporting excavation faces; selection and
separation of materials; forming and trimming; taking precautions to avoid damage to property; and
additional excavation for working space.
The Contractor shall be paid under item 42.01 for replacement of unsuitable materials with suitable
material.
Item 41.02 Roadbed preparation and compaction ............................................. cubic metre (m³)
The unit of measurement shall be the cubic metre of roadbed material prepared and compacted as
specified in Clauses 4102 and, 4103. The quantity shall be calculated in accordance with the
authorised dimensions of the completed layers.
The tendered rates shall include full compensation for shaping, scarifying and compaction; provision of
rollers; keeping the rollers ready for use when moisture conditions are favourable as specified; mixing
of in-situ and imported material if required; taking precautions to prevent damage to property; and
trials to demonstrate compaction methods.
No separate payment shall be made for roadbed preparation and compaction unless works as
indicated in Sub-clause 4103(c) are undertaken on the instruction, and to the satisfaction, of the
Engineer.

Item 41.03 In-situ treatment of roadbed

a) In-situ treatment by ripping ............................................................................. cubic metre (m³)
b) In-situ treatment by blasting ............................................................................cubic metre (m³)
The unit of measurement shall be the cubic metre of in-situ material treated in-situ as specified in sub-
clause 4103(d). The quantity shall be calculated in accordance with the authorised dimensions of the
completed in-situ treatment.
The tendered rates shall include full compensation for ripping or blasting, shaping, scarifying and
compaction; keeping the rollers ready for use when moisture conditions are favourable as specified;
mixing of in-situ and imported material if required; taking precautions to prevent damage to property;
and trials to demonstrate compaction methods.
Payment shall distinguish between in-situ treatment by ripping and in-situ treatment by blasting.
Surplus material shall be measured and paid for as in Division 4200.

Division 4200: Roadway and Borrow Excavation
4201 General
(a) Scope
This Division covers all work in connection with the excavation, stockpiling and use (or otherwise) of
soil and rock within the road prism (ie cut material) and borrow areas, except for the excavations for
foundations. It also covers work in connection with the excavation of soil and rock for diverting,
channelling or widening of streams further than 5 metres upstream or downstream of culverts or bridge
inlets and outlets respectively.
In addition, this Division covers widening of existing cuttings, fills and roadbeds.
(b) Dimensions
The dimensions of cuttings and other excavations shall be in accordance with the cross sections and
details as described in the Contract and further amended during the course of construction as
4202 Topsoil
After clearing and grubbing of the natural ground surface within the width of the road prism, the
Contractor shall remove topsoil, if instructed by the Engineer.
The Engineer shall indicate the depth to which the topsoil is to be removed; whether it is for reuse or
spoil; and the location of stockpiles, spoil areas or placement. The depth of removal of topsoil will be
either zero or an average depth between 150mm and 400mm.
Topsoil shall be stockpiled in heaps not more than 3m high.
4203 Borrow and Spoil

Where sufficient quantities of suitable material for use as fill are not available from roadway
excavations, additional materials shall be excavated from borrow pits indicated on the plans, or as
The quantity of spoil is equal to the total excavation of the Works minus the volume of suitable material
used to construct embankments to subgrade level; and minus the volume of suitable material used to
establish the subgrade level in cuttings (if the value is less than zero then spoil is equal to zero).
4204 Classes of Excavation
(a) Common (Normal or Soft) Excavation

Common excavation shall be excavation in material which can be efficiently removed or loaded by any
of the following equipment:
1. A bulldozer with a mass of at least 25 tonnes and an engine developing approximately 180 kW
at the flywheel; or
2. A tractor-scraper unit with a mass of at least 30 tonnes and an engine developing 245 kW at
the flywheel, pushed during loading by a bulldozer as specified in Sub-clause 4204(a)(1); or
3. A track-type front-end loader with a mass of at least 27 tonne and an engine developing 175
kW at the flywheel.

4. A bulldozer with a mass of at least 35 tonne, fitted with a single tine ripper and an engine
developing approximately 220 kW at the flywheel.
(b) Rock (Hard) Excavation

The following shall be classified as rock excavation:
1. Excavation in material which cannot be efficiently ripped by equipment as specified in Sub-

clause 4204(a).
2. Large boulders encountered in excavation which, in the opinion of Engineer cannot be
removed by mechanical excavator and can only be removed with the use of a compressor and
pneumatic breaker equipment or blasting.
3. Isolated volumes of artificial hard material or rock occurring within other material to be
3
excavated. This material shall only be measured separately when its volume exceeds 1m and
complies with the specified requirement in 4204(b)(2).
4205 Excavation of Unsuitable Material

Unsuitable Material shall be treated as specified in Sub-clause 4103(a).
4206 Method of Classifying

The Contractor shall be at liberty to use any appropriate method to excavate any class of material but
the method of excavation shall not determine the classification of the excavation.
The classification of the excavation shall be determined by the Engineer.
In the first instance the classification shall be based on an inspection and evaluation of the material to
be excavated. This classification shall be determined before excavation commences. In the event of a
disagreement between the Contractor and the Engineer, the Contractor shall, if required, make
available such mechanical equipment, at the Contractor’s cost, in order to determine whether or not
the material can reasonably be removed. Thereafter, the decision of the Engineer related to the
classification of the material shall prevail.
The Contractor shall immediately inform the Engineer if and when the nature of the material being
excavated changes to the extent that a new classification for further excavation is warranted. Failure
on the part of the Contractor to provide timely advice to the Engineer, shall entitle the Engineer, at his
sole discretion, to classify such excavations as may have been executed in a material of a different
nature.
4207 Construction Requirements for the Excavation of Cuttings
(a) Equipment
Equipment used for the excavation of cuttings shall be suitable for the type of material to be
excavated.
(b) General
The Contractor shall exercise proper care when excavating material not to loosen, where this can be
avoided, any material outside the specified cutting line, whether by ripping, blasting or other means,
thereby endangering the stability of the slopes and any adjacent property or personnel; or
subsequently causing undue erosion or disintegration of the batters.

Pre-split blasting or cushion blasting shall be used in preference to bulk blasting whenever the stability
of the excavated slopes is integral to the performance of the Works. Blasting shall only be permitted at
the discretion of the Engineer.
Care shall also be exercised not to undercut any slopes, and proper control shall, at all times, be
exercised by regular survey checking and the use of batter boards at close intervals. Where the
batters are nevertheless undercut, backfilling and compacting with imported material will not normally
be considered as a suitable remedy, and the Engineer may order additional, more appropriate
remedial measures to be carried out. This may, in serious cases, include cutting back the whole or
major portions of the batter to a uniform slope or the use of retaining structures.
Construction equipment shall not be used on the surface of the bottom of a cutting unless the cutting
is in rock containing no soft material; or the Contractor maintains the level of the bottom surface at
least 300mm above the finished subgrade level. The Contractor shall reinstate any damage to the
prepared subgrade level arising from such use of the surface at the Contractor’s own cost.
From the time the Contractor begins to trim the remaining material to subgrade level in cuttings or to
roadbed level for the construction of embankments up to subgrade level on any given area, the
movement and use of construction equipment thereon, other than that used to complete the
preparation of the subgrade, shall be kept to a minimum.
(c) Dimension of Cuttings

The dimensions of cuttings shall be in accordance with the cross-sections and details shown on the
Drawings and further amended during the course of construction, as instructed by the Engineer.
All cuttings excavated below the specified levels shall be backfilled with suitable material and
compacted to the satisfaction of the Engineer. The Contractor should anticipate that a certain amount
of over-break might be inevitable in hard excavation and should make adequate provision for this
eventuality in the tendered rate.
During excavation, the Contractor shall limit vertical and other temporary faces to such heights as are
suitable, related to the nature of the exposed soil. If any slips, slides or subsidence occurs as a result
of any slope being cut in any part more steeply than the design slope, the Contractor shall reinstate
the slope and make good any related damage to the satisfaction of the Engineer and at the
Contractor’s own cost; unless he can show that the slip, slide or subsidence was not due to his failure
to comply with the Specifications and/or the Drawings. The Engineer may, when he considers it
necessary, instruct the Contractor to widen cuttings already existing, completed or partially completed
either uniformly or by altering the slope of the sides of the cut; or by cutting benches; or in any other
way.
Any slopes caused to fail by the placement of temporary stockpiles or unapproved spoil dumps shall
be reinstated and any related damage repaired to the satisfaction of the Engineer and at the
Contractor’s own cost.
(d) Finish of Cut Slopes

Slopes in cuttings shall be finished in accordance with sub-clause 4403(m).
4208 Use of Excavated Materials

All material excavated from the road prism shall, insofar as is practical and in line with the
requirements of these Specifications, be used for the construction of embankment fills, pavement
layers and for such other purposes as shown on the Drawings or as directed by the Engineer.

The Contractor shall not dispose of any excavated material without the approval of the Engineer.
Excavated material, which is unsuitable for use in any part of the Works, or surplus to requirements,
shall be disposed of as specified in sub-clause 4208(e).
Coarse rock encountered in cuttings shall be utilised for the construction of the lower layers of deep
fills, or where so required, shall be conserved and used as directed for masonry or gabion stone; for
constructing the sides of embankments; and/or for serving as protection against embankment or
channel erosion.
The Engineer shall have full control of the use of all material from excavations of cuttings. However,
the Contractor shall plan his operations, and particularly his cut-to-fill operations, in such a manner
that all cut material may be used to the best advantage of the Employer. No material shall be
unnecessarily spoiled or borrowed. The Contractor shall neither borrow nor spoil any material without
the Engineer’s approval and without satisfying the Engineer that this is necessary and provides the
most economical method of constructing the Works.
Generally the Works shall progress in an orderly fashion with suitable material being cut to adjacent
fills. In general the excavated materials shall be placed directly in their final position in embankments.
Hauling of material from cuttings to embankments or other areas shall only take place when sufficient
compaction equipment is operating at the place of deposition to ensure compliance with the relevant
Clauses of this Division.
The Contractor shall only use equipment which is suited to the material to be handled. The Contractor
shall not, at any time, use any equipment which damages or reduces the natural strength of the
material more than is necessary; either in its in-situ state; or during handling and placing; or in its final
compacted state.
Where directed by the Engineer prior to commencement of work, the Contractor shall submit a
statement of his proposed plan of operation, and if so directed, the Contractor shall not commence the
work until the Engineer approves such plan. The plan shall be additional to any construction
programme required under the Contract.
(a) Stockpiling of Material

Where immediate utilisation of excavated material for use in embankment fills and pavement layers is
impractical, and if so instructed by the Engineer in writing, the material shall be temporarily stockpiled
at an approved site for subsequent loading and transporting to where it will be used. Compensation for
stockpiling materials shall be payable only in regard to material stockpiled in accordance with the
Engineer’s written instruction.
The temporary stockpiling of material within a borrow area in heaps with a view to loading, or any
other stockpiling method used in connection with the loading method adopted by the Contractor in the
cutting or borrow pit shall not be classified as temporary stockpiling. The cost of these processes shall
be deemed to be included in the rates for the various items of work for which material so stockpiled is
to be used.
Stockpiling areas shall be cleaned and cleared of all loose stones, vegetation and other deleterious
material which may cause contamination, and shall be indicated or approved by the Engineer.
After the stockpiled material has been removed, the site shall be reinstated as closely as possible to
its original condition; and the surface shall be lightly scarified to promote vegetation growth.
(b) Breaking down the Material

In order to achieve the required size specifications for materials to be used in fill and pavement layers,
two stages of breakdown shall be used.

(i) Initial Breakdown

The material from cuttings and borrow pits shall be initially broken down to the maximum sizes as set
out below depending on the use envisaged for the material prior to loading and hauling to the road for
use:
 Rock fill: 750mm maximum dimension

 General (Normal) fill: 500mm maximum dimension
 Pavement layers: 300mm maximum dimension
Spoil material need only be broken down to an extent that facilitates convenient loading and
transporting unless instructed otherwise by the Engineer.
Material intended for crushing need only be broken down to an extent that allows acceptance by the
crusher.
In order that the material can be broken down to the required sizes, the Contractor shall adjust and
control the blasting, ripping, excavating and other operations so that the desired result can be
achieved as effectively as possible. All blasting operations shall be undertaken with due consideration
of the requirements in Clause 1210.
If, in the opinion of the Engineer, the working methods of the Contractor are such that unnecessarily
large quantities of oversized material are produced, the Contractor shall be instructed to change his
methods in order to produce less oversize material and shall not be entitled to any additional
compensation for such changes in method.
Care shall be taken not to load oversize material and to transport it onto the road. Where this is
nevertheless done, the Contractor shall at his own cost, remove such oversize material from the road
and break it down further to the required size.
Where surplus material is available and the Engineer so agrees, the Contractor, instead of breaking
down oversize material, may work it out or leave it in the borrow pit; or in the case of material from
cuttings, may send to spoil with the written approval of the Engineer. The Engineer may also require
oversize materials to be used for other purposes such as for rock fills instead of breaking down.
(ii) Further Breakdown for Fill

Following the breakdown of fill material in cuttings and borrow pits to the maximum size specified in
sub-clause 4208(b)(i) and the spreading on the road, it shall be further broken down by means of
suitable equipment such as grid rollers subject to the approval of the Engineer.
In most cases, breaking down by the normal compaction process should be adequate and no special
effort should be required for breaking down the material. However, in the case of hard and coarse
material, the Engineer may require that the material receives at least a light grid rolling, and the
degree to which breakdown will occur by means of the light grid rolling process will then serve as the
norm for what may be required in regard to alternative methods the Contractor is permitted to employ.
For the purpose of these Specifications, light grid rolling is defined as follows:
 The material from the cutting or borrow pit shall be spread in a layer, the uncompacted
thickness of which shall be more or less equal to the average maximum fragment size, but
with a minimum of 200mm.
 The uncompacted layer shall be rolled by means of at least two (2) complete passes per
200mm of uncompacted layer thickness by a grid roller with a mass of not less than 13.5
tonnes moving at a speed of at least 12km per hour.

 Should the uncompacted layer thickness be in excess of 200mm, the number of roller passes
shall be increased pro-rata.
Compensation for light grid rolling will be regarded as being included in the price paid for providing
and compacting the material.
(iii) Further Breakdown for Pavement Layers

Pavement materials shall be further broken down to the sizes as specified for each layer by using grid
rollers and other suitable equipment, subject to the approval of the Engineer. The Contractor shall be
at liberty to employ any methods and equipment he may prefer, but where any difference of opinion
may arise in regard to the practicality of the breaking down process, or the suitability of the methods
and equipment employed by the Contractor, the Engineer may require normal grid rolling to be
undertaken as described hereafter. The results so obtained will then serve as the norm for the degree
of breakdown to be attained by any alternative method.
For the purpose of these Specifications, normal grid rolling shall mean the following steps:
1. The material shall be placed or bladed to one side of the road to provide working space for
breaking down the material.
2. Subject to the approval of the Engineer, a portion of the material shall be spread in a thin layer
on a compacted surface to promote effective breaking down of material and to a width which
the grid roller shall be able to cover in a single pass.
3. The grid roller shall have a minimum mass of 13.5 tonnes operating at a speed of at least
12km per hour and shall do four (4) complete roller passes over the material.
4. Any oversize material shall be removed by hand and/or construction plant as indicated in sub-
clauses 4208(b)(i) and 4208(e).
5. The broken down material shall be placed in a windrow to the opposite side to the material still
to be broken down.
6. Repeat steps 2) to 5), but place the second windrow next to the first.
7. Mix the material in the two windrows formed in steps 2) to 6) by blading into a single windrow
to the side of the road.
8. If so ordered by the Engineer, repeat steps 2) to 7) until all the material that needs to be
broken down has been treated to the satisfaction of the Engineer.
Should too much oversize continue to be produced by normal grid rolling, the Engineer may instruct
that any one of the following be done:
 Additional normal grid rolling or its equivalent;

 Crushing as described in sub-clause 4208(c); or
 Breakdown by the use of any other suitable equipment approved by the Engineer.
Any oversize still remaining after processing in accordance with this sub-clause shall be considered to
be surplus material and disposed of at the Contractor’s own cost, or with the approval of the Engineer,
may be used for other suitable purposes.
(c) Crushing and Screening

Where the material intended for use in the pavement layers cannot be suitably broken down by the
methods set out in Sub-clause 4208(b)(iii), the Engineer may direct that the material be crushed,
screened, or crushed and screened, or be modified by screening out certain fractions.
A single-stage crushing plant implies the utilisation of a primary crushing unit in which only one size
reduction stage occurs, irrespective of the magnitude of the reduction ratio possible by nature of its

construction. The single stage crushing plant shall be capable of breaking down oversize material to
the maximum size specified for the layer concerned.
A second crushing stage, while not always necessary to achieve the required reduction ratio, is
required by utilising a secondary crushing plant in addition to the primary crushing unit, to control the
grading of the product to fall within the broader specified envelope for sub-base, road base and lower
quality selected materials, as well as yielding specified shape characteristics as appropriate. This shall
be termed a two-stage crushing plant.
A third crushing stage and where appropriate a fourth crushing stage utilising in addition to the earlier
stage crushing plant, tertiary and quaternary crushing plants, as appropriate, to control the grading
and shape of the higher quality pavement materials as well as grades of surfacing aggregate and
concrete aggregates, shall be termed a multi-stage crushing plant.
For the single-stage and two-stage crushing plant, selective screening may be ordered by the
Engineer.
Screening only of material involves screening the material into various fractions through a series of
screens, the smallest of which need not be smaller than 6.7mm.
For the multi-stage plant, all screening and/or any other required activity and concomitant equipment
required to produce the specified end product, shall be considered to be included.
For all stages of crushing plant, precautionary measures required in terms of occupational health,
safety and the environment and other relevant national legislation (and the latest amendments thereof)
as required in Division 1600 shall be deemed to be included in the rates tendered for the relevant
products.
(d) Control of Moisture Content

The Contractor shall take all reasonable precautions to prevent material in borrow pits, excavations,
stockpiles and on the road from becoming excessively wet as a result of rain or groundwater or
stormwater. In view hereof, the excavation of borrow pits and cuttings shall, as far as possible, be so
planned and executed as to prevent the damming-up of water in the borrow pits or cuttings, and the
Contractor shall also provide the necessary temporary drainage for this purpose. During the rainy
season, material spread over the road shall be spread with a proper cross slope, and if not directly
compacted, it shall be rolled several times with a flat-wheeled roller in order to let the water run off the
surface and not penetrate the material unduly. Care shall also be taken not to allow the water to dam
up against material heaps, windrows, or any spread material.
Where material, despite proper precautionary measures, on account of its in-situ moisture content, is
nevertheless too wet to comply with the requirements in regard to moisture content during compaction,
the Contractor shall dry out the material until it is adequately dry for compaction. However, where
practical, the Contractor shall plan his construction programme so that material with a high natural
moisture content shall be used in the dry season and not in the wet season.
No prescriptions apply in regard to drying out the material and the Contractor shall decide on the best
methods. No additional payment will be made for keeping dry and drying out the material, but the cost
of such work shall be included in his tender rates for the various items of work for which the material is
to be used, unless provision for additional compensation of this nature has been made in the
Particular Specifications.

(e) Disposal of Oversize and Surplus Excavated Soil or Rock

The Contractor shall not dispose of any excavated soil or rock without the prior approval of the
Engineer.
All oversize material removed from the road in terms of Sub-clause 4208(b) and surplus fill material as
specified in Sub-clause 4403(d) shall be disposed of as instructed by the Engineer or may be used for
other suitable purposes with approval by the Engineer. The tendered rate for constructing all fill and
pavement layers shall include full compensation for the removal and disposal of all oversize and
surplus materials.
Excavated soil or rock which is either unsuitable for use in the Works; or oversize; or is surplus to
requirements, shall be disposed of in specially designated areas identified by the Contractor and
approved by the Engineer. If necessary, the area shall be cleared and grubbed in accordance with the
requirements of Division 2100 prior to the surplus soil or rock being deposited; spread in layers; and
compacted to the approval of the Engineer. After compaction, the surface and slopes of the finished
disposal area shall be trimmed to the satisfaction of the Engineer.
All disposal operations shall take due note of the general requirements in Clause 1604 of these
Specifications.

(a) General Directions
(i) Determining the Quantities

Upon completion of all works in connection with clearing and grubbing, and where the classification of
the excavations of the road prism and borrow areas change, the Contractor, at his own cost, shall take
cross-sections at 20m intervals so as to determine quantities, and shall submit the results so obtained
to the Engineer for approval. The Engineer shall take control measurements to determine the accuracy
and adequacy of the cross-sections. The Engineer shall also instruct the Contractor to correct any
disputed measurements and to take such additional measurements and cross-sections as may be
deemed necessary by the Engineer. Such cross-sections shall be taken before any cut or fill work is
undertaken by the Contractor in material where the classification of the excavation is considered to
have changed by the Contractor. Where the Contractor proceeds with such work before final approval
of the cross-sections and quantities where the classification of excavations is deemed by the Engineer
to have changed, and before the Contractor and the Engineer have agreed on the cross-sections, the
Engineer’s decision regarding the cross-sections to be used shall be final and binding on the
Contractor.
Where cross-sections for the classification of excavations have been agreed between the Engineer
and the Contractor and, during subsequent construction of fills on the completed roadbed, there are
valid reasons for believing that the roadbed is subsiding, the Contractor may request that the fill
quantities shall be adjusted accordingly. Such requests shall be lodged without delay, and the
Contractor shall submit the required supporting evidence of the subsidence to the Engineer. Where
the Engineer is satisfied that significant subsidence is occurring, the Engineer, together with the
Contractor, shall decide on the extent of the subsidence. Where no agreement can be reached, the
decision of the Engineer shall be final. Any adjustments of this nature shall be made only where the
average subsidence exceeds 50mm.
(ii) Material from Commercial Sources

If specified in the Particular Specifications, material from commercial sources shall be used for the
construction of fills. In such cases the items listed below shall be applicable, except that the tendered

rates shall also include full compensation for all transport costs, and no overhaul shall be measured
and paid for.
(iii) Work in Restricted Areas

Special rates for works in restricted areas are applicable solely to work that has to be executed in an
area of which the width is less than 3m or the length is less than 150m.
Item 42.01 Cut and borrow to fill

a) Cut to fill material:
3
(i) Compacted to 90% of modified AASHTO density ......................... cubic metre (m )
3
(ii) Compacted to 93% of modified AASHTO density ......................... cubic metre (m )
3
(iii) Compacted to 95% of modified AASHTO density ......................... cubic metre (m )
3
(iv) Capping layer or Improved/selected subgrade ............................. cubic metre (m )
b) Borrow to fill material (including all specified borrow pit requirements under Division 4300):
3
(i) Compacted to 90% of modified AASHTO density ......................... cubic metre (m )
3
(ii) Compacted to 93% of modified AASHTO density ......................... cubic metre (m )
3
(iii) Compacted to 95% of modified AASHTO density ......................... cubic metre (m )
3
(iv) Capping layer or improved/selected subgrade .............................. cubic metre (m )
The unit of measurement shall be the cubic metre of material measured in the compacted fill. The
quantity measured shall be calculated by the method of average end areas from levelled cross-
sections prepared from the ground line after clearing and grubbing, the removal of topsoil and the
completion of any preparatory roadbed treatment which may have been ordered by the Engineer; but
prior to the construction of the fill; and the final specified or authorised fill cross-section superimposed
thereon at 20m intervals along the centreline of the road.
All measurement shall be neat, and that part of the fill placed in excess of the authorised cross-section
shown on the Drawings or directed by the Engineer, will not be paid for irrespective of the tolerances in
workmanship allowed under the contract. Where the roadbed has subsided under the fills, the
quantities shall be adjusted to make allowance for such subsidence, as set out in sub-clause
4209(a)(i).
Measurement and payment of fill shall distinguish between the type and source of fill and the minimum
compaction density related to the depth of the layer within the fill as specified on the Drawings or as
Material excavated for the construction of open drains, sub-soil drains, culverts, bridge foundations
and other structures, shall, if suitable and if so directed by the Engineer, be used for the construction
of fills, and payment shall be made under this item irrespective of any payment made previously for
the excavation of such material. All such material shall be classified as common (normal or soft)
excavation.
The tendered rates shall include full compensation for procuring, furnishing, transporting and placing
the material, including excavating as if in common (normal or soft) excavation; the removal of
overburden in borrow areas; the cutting of benches; for preparing, processing, shaping, watering,
mixing, and compacting the materials to the densities required on the Drawings or in the manner
specified herein; forming, trimming and finishing all slopes; replacing materials rendered unsuitable
with suitable material as approved by the Engineer; selection and separation of materials; taking

precautions to avoid damage to property; additional excavation for working space; and for removal and
disposal of oversize or surplus material from the road after processing, including all transport.
The tendered rates shall also include full compensation for the supply and installation of synthetic-fibre
filter material where specified or indicated on the Drawings.
Item 42.02 Extra over item 42.01 for excavating and breaking down material
a) Common (normal or soft) excavation .............................................................. cubic metre (m³)
b) Rock (hard) excavation .....................................................................................cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated and broken down as
specified.
Measurement of items (a) and (b) shall be in the original position in the cut or borrow pit and the
quantity shall be calculated by the method of average end areas from levelled cross-sections at
intervals not exceeding 20m measured along the centreline of the road in the case of cuts and at
intervals not exceeding 10m and parallel to one another in the case of borrow pits before and after the
removal of the material.
The tendered rates shall be paid as extra over the rates applying to common (normal or soft)
excavation in item 42.01 and shall include full compensation for additional costs to excavate and break
down the various classes of material including the cost of all the necessary additional equipment,
transport, labour and supervision.
The extra over payment shall distinguish between common (normal or soft) and rock (hard) as defined
in Clause 4204.
Item 42.03 Cut to spoil

a) Common (normal or soft) excavation ...............................................................cubic metre (m³)
b) Rock (Hard) excavation ....................................................................................cubic metre (m³)
The unit of measurement shall be the cubic metre of material measured in its original position in cut
and calculated by the method of average end areas from levelled cross-sections taken along the
existing ground level after clearing and grubbing and the removal of topsoil, if any; but prior to
excavating the cut with the final specified or authorised cross-section of the cut superimposed thereon
at intervals not exceeding 20m along the centreline of the road.
The measurement shall also be based on the volume of suitable cut minus the volume used in fill for
10 km project lengths without any adjustment for expansion or shrinkage of cut or fill sections
respectively. The mass balance shall be undertaken for 10 km road sections. Disposal of surplus or
unsuitable material shall be made at approved spoil sites. Side waste shall be prohibited in line with
environmental regulations.
The tendered rates for cut to spoil shall include full compensation for excavating from the road prism
and roadbed in the various classes of excavation; temporary storage and multiple handling; and for
loading, transporting, off-loading and disposing of the material as specified, including any spreading,
grading, shaping, watering, mixing, compacting and levelling-off any piles of spoil material in approved
areas of disposal.
This payment item shall also apply to the removal of unsuitable roadbed material (as described in
Division 4100) provided that the instruction in respect of its removal is given before the excavations
reach the level of the roadbed. Any unsuitable materials identified for removal to spoil after reaching
the level of the roadbed shall be measured and paid under item 41.01.

3
Item 42.04 Stockpiling of material ....................................................................... cubic metre (m )
The unit of measurement shall be the cubic metre of material temporarily stockpiled on the instruction
of the Engineer.
The tendered rate shall include full compensation for cleaning and preparing the stockpiling sites and
also for levelling and reinstatement of the site after completion of the work; for offloading and
spreading the material as necessary; and for loading and transport when required for use.
Item 42.05 Widening of cuts (extra over items 42.01, and 42.03)
a) In rock (hard) material ...................................................................................... cubic metre (m³)
b) In all other materials ......................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated during the widening of cuts
where they are more than 2.5m deep (measured vertically from the top of the cut to the shoulder
breakpoint), and where the cut is widened by less than 4m.
Measurement of the material shall be in the original position in the cut and the quantity shall be
calculated by the method of average end areas from levelled cross-sections at intervals not exceeding
20m measured along the centreline of the road before and after removal of the material.
The tendered rates for widening the cuts shall be paid extra over the rates tendered for items
42.01 (a), and 42.03 and shall include full compensation for the additional costs involved (over and
above those for excavating new cuttings) for excavating material during the widening of a cut where
the cut exceeds 2.5m in depth and is widened by less than 4m.
Item 42.06 Crushing and screening

a) Single stage crushing ....................................................................................... cubic metre (m³)
b) Two-stage crushing .......................................................................................... cubic metre (m³)
c) Screening ......................................................................................................... cubic metre (m³)
d) Multi-stage crushing and screening ................................................................. cubic metre (m³)
The unit of measurement shall be the cubic metre of material crushed or screened; or crushed and
screened; for final use in construction, measured in place after compaction.
No allowance shall be made for waste, except in the case of sub-items (c) and (d) where the quantity
measured for payment shall be increased by including 70% of the loose volume of the material
screened out and discarded, measured in stockpile.
The tendered rates shall include full compensation for crushing in the case of sub-items (a) and (b); or
screening in the case of sub-item (c); or crushing and screening the material in the case of sub-item
(d); including all labour, plant, fuel, handling, processing, stockpiling if necessary, loading and
transportation to the point of final use, and for disposal of any material screened out and discarded.

Division 4300: Borrow Materials
4301 Scope
This Division covers the work involved in obtaining materials from borrow areas for construction of the
Works. It includes clearing the site; stripping overburden, including topsoil; excavating selected
material for use in the Works; and reinstatement of the borrow area.
4302 Obtaining Borrow Materials
(a) Borrow Area Locations

Borrow material shall be located and excavated for use by the Contractor. Borrow material shall
comply with the requirements of the Specifications related to the intended use of the material.
The Contractor shall excavate the necessary trial holes; obtain sufficient representative samples; and
perform, or have performed such tests as are necessary to assess the suitability of the material for use
in the Works. The Contractor shall submit all the results to the Engineer in sufficient detail to satisfy
him that the quality and quantity of material available in the proposed borrow area are acceptable for
the intended use.
Approval of borrow areas shall apply only to those portions of the area(s) from which acceptable
material can be obtained or produced. The Contractor shall conduct his operations in any approved pit
or borrow area or portions thereof so as to produce acceptable material.
Any approval given by the Engineer shall not relieve the Contractor of the responsibility of ensuring
that material obtained from a borrow area complies in all respects with the specification for the
material.
(b) Use of Borrow Materials

The Engineer shall not approve the use of any material from borrow areas unless the Contractor has
made full use of all available materials arising from excavations within the Site.
4303 Opening and Working of Borrow Areas
(a) Removal of Topsoil

Prior to the opening of a borrow area the Contractor shall ascertain from the Engineer whether the
removal of topsoil is required and shall remove and stockpile such topsoil as instructed by the
Engineer.
(b) Clearing and Grubbing

Only under the following circumstances, prior to the commencement of excavation of the borrow area,
shall clearing and grubbing of borrow areas be measured for payment in accordance with the
provisions of Division 2100 of these Specifications, unless otherwise directed by the Engineer:
 In borrow areas located in plantations;

 In borrow areas where no excess overburden exists; but the removal of grass, shrubs and
roots is required;
No clearing and grubbing will be measured or paid for in borrow areas opened for obtaining rock or
sand used in the construction of stone pitching, concrete work, crushed stone base or sub-base,
permeable subsurface drain material or for bituminous asphalt or surfacing.

(c) Overburden
The Contractor shall advise the Engineer in good time of his intention to operate from any borrow area
before any excavation at such borrow area is commenced, in order that a survey of the site can be
made for the purpose of calculating the quantity of overburden, if any, to be removed.
No removal of overburden or any other quarrying operations shall proceed until agreement has been
reached between the Engineer and the Contractor with regard to the quantity of such overburden.
Where overburden is identified and the quantity approved by the Engineer for removal, this will include
all clearing and grubbing operations. Overburden shall be removed as instructed by the Engineer, to
the outer limits of the proposed borrow area. If this area is later increased, the overburden shall be
removed further to the new outer limits of the borrow area; or where possible at that stage, used as
backfill to exploited borrow areas as part of the borrow area reinstatement as described in Clause
4304.
(d) Excavation of Borrow Material

Where any borrow area contains different types of material in separate layers which are required to be
mixed in order to produce a suitable product, the material shall be excavated over the full depth of the
approved face in one operation without separation of the different types of material.
The Contractor shall exercise all reasonable care so as to avoid contamination of approved borrow
material by the inclusion of excess clayey or otherwise unsuitable material from the floor of the borrow
area; from overburden; from unsuitable layers; or from areas beyond the approved limits of the borrow
area. During loading, hard oversize material which will not break down during processing on the road
shall be excluded as far as is practical, including if necessary the use of a grizzly for screening out the
oversized. During the course of borrow operations and especially when excavating near the floor and
outer boundaries of borrow areas, the Contractor shall plan his operations so as to reduce, as far as
possible, the amount of earthmoving that will be necessary for the final reinstatement of the borrow
area. Indiscriminate excavation without due regard for the desired final shape of the borrow area shall
not be permitted.
The material in borrow areas shall be blasted, ripped or excavated in a manner that will ensure the
effective break down of the material. Any oversize particles in material to be used for sub-base, road
base or gravel wearing course shall be removed by screening or other approved means before it is
taken from the borrow area.
(e) Control at Borrow Areas

The Contractor shall be responsible for controlling his operations at every borrow area where material
is being excavated to ensure compliance with the requirements of this Clause.
The Contractor shall carry out sufficient tests on the material being excavated from the borrow area in
order to satisfy himself that the quality of the material will comply with the specified requirements for
the particular layer for which it will be used.
If there is any doubt concerning the quality of borrow material being excavated at any time, the
Contractor shall notify the Engineer immediately, and in any case, before such material is brought onto
the Works. The result of all tests carried out by the Contractor, shall be submitted to the Engineer. The
Engineer will, after further testing, or inspection if necessary, instruct the Contractor regarding the use
of the material from the borrow area; or order the borrow area to be reinstated and abandoned.

(f) Protection of Borrow Area

Borrow areas shall be continuously protected against the ingress of surface water and the Contractor
shall construct such temporary banks as may be required to divert surface water. As far as possible,
his operations shall be planned in such a way that the borrow area is self-draining. Where this is not
possible, borrow areas shall be dewatered by pumping. The Contractor shall be solely responsible for
keeping borrow areas dry and ensuring that borrow material is sufficiently dry when required for use.
4304 Reinstatement of Borrow Areas

On completion of his operations in a borrow area the Contractor shall reinstate the entire area so as to
blend with the surrounding area and to permit the re-establishment of vegetation. For this purpose the
borrow area shall be shaped to even contours. All material in and around the borrow area, whether
spoil from road building operations; excess stockpiled material; oversize material left in the borrow
area; material resulting from clearing and grubbing operations; and overburden, shall be used or
disposed of as directed by the Engineer. Material not capable of supporting vegetation shall be buried,
used in shaping the borrow area and subsequently covered with soil capable of supporting vegetation.
This soil shall be spread evenly to the thickness directed and where sufficient material is not available
for this purpose to cover the entire area, the remaining portions shall be scarified along the contours
so as to avoid undue erosion.
The shaping and reinstatement of the borrow area shall be done in such a way that the borrow area
will be properly drained whenever practicable and where required, the Contractor shall place earth
banks to divert any surface water away from the borrow area.
Attention is also drawn to the requirements of Division 1600 in this regard.
4305 Disposal of Borrow Material

The Contractor shall not have the right to use material obtained from borrow areas for any purpose
other than for the execution of the Works and shall not dispose of any borrow material, whether
processed or not, either by sale or donation, to any person without the written authority of the
Employer.
4306 Classification of Borrow Areas for Gravel Materials for Pavement Layers
Excavation of borrow areas for the production of gravel materials for pavement layers shall be
classified in accordance with the same classification described in Clause 4204. The Engineer shall
decide which borrow area shall be operated by the Contractor at any particular stage of the work and
may approve new borrow areas during the construction period.
4307 Establishing a Crushing Plant for Crushed Stone Base and Sub-base
from Borrow Areas
Where the Contractor is required to establish a crushing plant for the provision of crushed-stone base
or sub-base from an approved borrow pits, whether indicated on the borrow-pit drawings or approved
after construction has started, the Contractor shall be entitled to compensation under Pay Item 43.02,
provided that prior instructions have been obtained from the Engineer to establish a crushing plant to
crush such material.
No payment shall be made under item 43.02 if the crushed stone material is supplied from commercial
sources or from a crusher that had been erected or was in operation prior to the award of the Contract,
or from a crusher that is not completely or directly under the control of the Contractor.

Compensation for the work performed in accordance with the supply and construction of crushed
stone base and sub-base shall be in accordance with Divisions 5100 and 5200.

Item 43.01 Reinstatement of borrow areas

a) Rock (hard) material. .............................................................................................. hectare (ha)
b) Common (normal or soft) material .......................................................................... hectare (ha)
The unit of measurement for reinstating borrow areas shall be the hectare measured in accordance
with the finally excavated area of the borrow pit before it is reinstated.
The tendered rates shall include full compensation for reinstatement of the borrow pits as specified in
Clause 4304 and to the satisfaction of the Engineer, including any necessary earth moving.
Borrow pits shall be classified in accordance with the classification of the material removed therefrom
as specified in Clause 4204 and where more than one class of material is taken from a borrow area,
the area shall be apportioned pro rata for classification purposes, in accordance with the volumes of
each type of material removed.
Item 43.02 Establishing a crushing plant in borrow pits for crushed stone .......................... No
The unit of measurement for establishing the crushing plant in borrow pits shall be the number of times
the plant is set up and dismantled, with the written approval of the Engineer, at approved sources of
supply, for the purpose of supplying crushed-stone material for base and sub-base.
The tendered rate shall include full compensation for the provision and erection of the crusher ready
for crushing, its later dismantling and removal after completion of the crushing operations.

Division 4400: Embankment Construction
4401 General
(a) Scope
This Division covers all work in connection with the construction of embankments within the road prism
up to the subgrade level (including capping or selected subgrade layers as specified in Clause 4104);
selected fill in shoulders; and medians and island fill; using soil or rock excavated from the road prism
or from approved borrow areas in accordance with Division 4200 and conforming with the lines,
grades, cross-section and dimensions shown on the Drawings, or as instructed by the Engineer.
(b) Sources of Materials

Materials used for the construction of embankments shall be obtained from cuttings, trenches or
foundations within the limit of the Works; or from borrow areas identified by the Contractor and
4402 Material Requirements for the Construction of Embankments

Unless otherwise specified in the Particular Specifications embankment materials (excluding rock fills
covered in Clause 4404) shall conform to the following requirements:
(a) Particle Size

The material shall not contain any fragments with a maximum dimension exceeding 500mm after initial
breakdown as specified in Clause 4208 (b)(i) for further processing and breakdown by grid rolling as
part of the Works (except in the case of rock fills when it may be 750mm after initial breakdown).
The material shall be well graded with a maximum particle size of less than 150 mm after breakdown
with a grid roller so that it can be readily placed within a 200 mm layer.
For lower layers of fill thicker than 200mm, the fill material shall not contain particles with a maximum
dimension exceeding two-thirds of the specified layer thickness after compaction (except in the case of
rock fill as specified in Clause 4404).
The minimum grading modulus for material to be used for capping or selected layers shall be 0.75
(b) California Bearing Ratio (CBR)

The fill material shall have a minimum soaked CBR of not less than 5% and a swell value of not more
than 2% (with two surcharge rings) when determined in accordance with AASHTO T-193 at a modified
AASHTO density of 95% of the maximum dry density determined in accordance with the requirements
of AASHTO T-180 method D.
(c) Liquid Limit (LL) and Plasticity Index (PI)

The fill material shall have a liquid limit not exceeding 60 and a plasticity index not exceeding 30 when
determined in accordance with the requirements of AASHTO T-89 and T-90.
(d) Compaction
Lower layers of embankment fill constructed on the prepared roadbed shall have minimum densities of
90, 93 or 95% of modified AASHTO density as shown on the Drawings or as instructed by the
Engineer. The upper layer of the embankment fill that constitutes the subgrade layer (including
capping and selected layers) shall be compacted to a minimum of 93% or 95% of modified AASHTO
density as shown on the Drawings, or as instructed by the Engineer.

Sand, which for the purpose of this requirement is specified as non-plastic sand with not less than
95% passing the 4.75mm sieve, but with not more than 20% passing the 0.075mm sieve shall be
compacted to 100% of modified AASHTO density. Should more than 20% pass the 0.075mm sieve,
the sand shall be compacted to 95% of modified AASHTO density on approval of the Engineer.
Where existing fills are to be widened or where new fills are to be constructed adjacent to existing fills,
the material shall be compacted to at least 93% or 95% of modified AASHTO density as required to
minimise differential settlement. For sand the compaction shall be at least 95 or 100% of modified
AASHTO density as shown on the Drawings.
Measurement and payment for compaction of cut and borrow materials to embankment fill shall be
effected under payment item 42.01.
4403 Construction Requirements for General Embankment Fills

The dimensions of fills shall be in accordance with the typical cross-sections shown on the Drawings;
or as amended by the Engineer during the course of construction. Prior to the start of construction, the
Contractor shall obtain instructions from the Engineer regarding the required slope of each fill; any
roadbed preparation or subsoil drainage required; detail of earthworks at interchanges and
intersections; the selection of materials; the method and classification of compaction; and any other
matter that may affect the construction of the fill or sequence of operations.
(a) Layer Thickness

The thickness of each compacted layer of the fill shall generally be determined by the maximum size
to which the material from the excavations or borrow pits can be broken down and thereafter, when it
is processed on the road. The layer thickness will therefore normally be based on the pre-estimation of
the maximum size to which the material can be broken down and shall be such that the maximum size
of the fragments shall be more or less two-thirds to the layer thickness after compaction.
Fill, other than rock fill, shall be deposited in layers not exceeding 200mm after compaction. Each
layer shall extend over the full width of the embankment and shall be placed in successive layers
approximately parallel to the final road surface. The construction of tapered layers shall be restricted to
the bottom layers of embankments where this may be unavoidable due to cross-fall, tapering out of
fills or super elevation of the final road surface.
On approval by the Engineer, material may be compacted in layer thicknesses in excess of 200mm or
the maximum fragment size provided that the Engineer is satisfied that the material will be properly
compacted to the specified density.
When a new layer is constructed on an existing or already constructed fill, and the new layer will be
less than 100mm in compacted thickness, the existing fill shall be scarified to such a depth as will give
a layer thickness after compaction of not less than 100mm of the new, plus the scarified material
together. No additional payment will be made for this operation.
(b) Equipment
Fill material shall be compacted by the use of purpose-made compaction equipment, which shall apply
uniform compaction effort across the full width of the machine. Each type of fill material shall be
compacted by equipment, which is suitable for the purpose.

(c) Spreading of Materials

Fill material shall be deposited on the compacted, underlying surface and evenly spread over the
whole of the designated area of the layer concerned in such quantity that the thickness of any one
layer, when measured after compaction, shall comply with the specified requirement.
Any new layer of less than 100mm in compacted thickness shall be mixed in to the previous layer by
scarifying to such a depth that the total compacted thickness of the new layer plus the scarified portion
of the previous layer shall not be less than 100mm.
(d) Oversize Material

Any oversize particles which are not broken down to comply with the requirements of Clause 4402(a),
prior to compaction, shall be removed from the layer and disposed of in accordance with the
requirements of Clause 4208(e).
(e) Placing and Compaction

The moisture content of fill material, other than rock fill, at the time of compaction shall be the optimum
for the equipment being used and not more than 2% above the optimum for the material determined in
accordance with the requirements of AASHTO T-180.
The layer thickness for fill material after compaction shall be 200mm or less. Any oversize material
which cannot be broken down to the required size as specified in Clause 4208 shall be removed from
the road and disposed of in line with Clause 4208, or used as instructed by the Engineer. The material
shall then be sprayed with water, mixed and compacted as described hereafter.
Prior to compaction, the material shall be thoroughly mixed by grader or other suitable plant so as to
obtain an even mix of the fine and coarse material throughout the mixture. Where necessary during
the mixing process, water shall be sprayed evenly over the material and mixed into the material to
bring it to the optimum moisture content for the compaction equipment being used.
In restricted areas, the Engineer may permit the Contractor to spread water and mix the material in a
windrow next to the pavement. In such cases care shall be taken not to damage existing compacted
surfaces and not to pollute the mixed material with other deleterious materials. Where this method of
mixing is impractical or impossible the Contractor shall make use of concrete mixers or any other
mixing equipment or method acceptable to the Engineer. Irrespective of the layer concerned, the
mixing shall be of such quality that a uniform mix shall be obtained at all times to the satisfaction of the
Engineer.
Compaction shall be carried out in a series of continuous operations covering the full width of the layer
concerned.
The Engineer reserves the right to order the Contractor to reduce the length of any layer compacted in
any single operation if the proper compaction of such a layer is not being achieved.
The type of compaction equipment to be used and the amount of rolling to be undertaken shall be
such as to ensure that specified densities are obtained without damage to lower layers or structures.
During compaction the layer shall be maintained to the required shape and cross-section; and all
holes, ruts and laminations shall be removed.
Suitable equipment and methods acceptable to the Engineer shall be used in restricted areas so that
the required densities will be obtained throughout the thickness of the layer. Work that has to be done
in restricted areas as a result of the actions of the Contractor shall not be regarded as work in
restricted areas for payment purposes.
In the case of cohesionless sand, the layer thickness may be increased to up to 400mm on approval
by the Engineer. Subject to the required density being achieved over the full depth of the layer,
spraying and mixing the material may be omitted or limited. In this case, suitable vibratory rollers,
approved by the Engineer, shall be used to compact the sand.
(f) Benching
Where the slope of the existing ground, in any direction is greater than 20%, the existing ground shall
be excavated to form horizontal benches which shall be a minimum of 2 m wide or otherwise, as
described in the Contract. Each bench shall be excavated as the fill material is compacted and the
embankment is raised. This requirement shall also apply to embankments constructed on rock with
slopes greater than 20%.
Suitable material excavated from the benches shall be incorporated into the embankment.
(g) Pioneer Layers

Where fill is to be constructed on water-logged or soft clayey ground exhibiting excessive movement
under normal compaction equipment and haulage vehicles, and such conditions preclude the effective
compaction of the bottom fill layers, the Engineer may direct that a pioneer layer be constructed on the
unstable ground. This layer shall be constructed by successive loads of suitable coarse material being
deposited and spread in a uniform layer with a nominal thickness of 100 - 200mm that is just sufficient
to provide a stable working platform for constructing the further fill layers which are to be compacted to
the specified density. It is common practice to allow a pioneer layer to “stand” through one (1) rainy
season. Light haulage equipment shall be used and the layer shall be compacted by light compaction
equipment to provide the most effective compaction without the roadbed being overstressed. After
standing for one (1) rainy season, the pioneer layer shall be treated as the first layer of fill.
(h) Construction of Drainage Blankets

Drainage blankets shall be constructed with natural filter material complying with the requirements of
Clause 3107.
The surface on which the drainage blanket is to be constructed shall be smooth and even and the filter
material shall be spread to an even thickness as required and lightly compacted with suitable rollers.
The final surface of the drainage blanket shall be finished off true to line and level.
(i) Construction of High Embankments

The construction of high embankments may require special techniques to prevent the development of
excessive pore pressure in the road bed and ensure the stability of such embankments during and
after construction. These may include inter alia the selection of better class material for use in the
bottom layers of the embankment; the construction of sand filter blankets; and the strict control of
moisture content during compaction. Where these measures are required, such embankments shall be
designated as high embankments, which shall be constructed in accordance with the requirements of
this Clause.
(j) Sand Fill and Sand Filter Blankets

Sand, which for the purposes of this requirement is specified as non- plastic sand with not less than
95% passing through the 4.75 mm sieve, but with not more than 20% passing through the 0.075 mm
sieve, shall be compacted to 100% of density. Should more than 20% pass through the 0.075 mm
sieve, the sand shall be compacted to 95% of modified AASHTO density on approval by the Engineer.
At the bottom of embankments, and sometimes at intermediate levels, the construction of sand filter
blankets may be required to facilitate the drainage of fills. Sand filter blankets shall be constructed in
accordance with the Drawings and shall normally consist of a layer of selected sand with a suitable

grading to provide effective drainage and to prevent the infiltration of fill or roadbed material into the
sand filter blanket. The surface on which the sand filter blanket is to be constructed shall be smooth
and even. The sand shall then be spread evenly to the required thickness and given a light
compaction with suitable rollers. The final surface of the sand filter blanket shall be finished off true to
line and level.
The Engineer may require the layers immediately below and above the filter blanket to be constructed
from selected soil or gravel.
(k) Construction of Fills near Structures (excluding structural backfill)

At all embankments adjoining uncompleted structures such as bridges and large culverts, where the
construction of the embankment and the backfilling behind the structure cannot be done
simultaneously, the embankment shall be so constructed that the longitudinal slope of the surface of
the embankment at all stages will form a continuous plane sloping towards ground level at the
structure, at a gradient not exceeding 10%. When the structure is completed, the remaining portion of
the embankment shall be similarly completed simultaneously with the backfilling behind the structure
to the required elevation.
(l) Widening of Fills

Where existing fills are to be widened, the existing fill slope and the roadbed onto which the new fills
are to be constructed shall be cleared and grubbed as instructed by the Engineer. The clearing and
grubbing shall be done in accordance with the provisions of Series 2000.The new roadbed shall be
treated in accordance with Clause 4103.
Where existing fills are required to be widened or where already constructed fills are required to be
widened or flattened, it shall be done by bench construction as prescribed in Sub-clause 4403(f) in
order to form a bond. Benches of not more than 500 mm deep shall be cut into the existing fill. In the
case of fills of less than 1m high, and in the upper one (1) metre of any fill, the benches shall not be
deeper than the layer thickness prescribed for constructing the widening, depending on whether or not
uncompacted fill material occurs in the side of the existing fill. The benches shall extend into the
properly compacted portion of the original fill material to the satisfaction of the Engineer.
All suitable material from the benches shall be used in the construction of the widened section of the
fill. Unsuitable material shall be removed as instructed by the Engineer. Benches shall be compacted
together with the fill widening during the construction of the fill.
Material in benches used in fill shall be paid for as “cut to fill” in pay item 42.01.
Where existing fill consists of rock fill, the new section shall consist of rock fill unless otherwise
approved by the Engineer. Rock fills shall not be required to be widened by less than 4m. Where
narrower widening of rock fill is required, the construction and payment thereof shall be covered in the
Sub-soil drainage required by the Engineer in the widening of fills shall be paid Division 3100.
(m) Finishing of Slopes

This sub-clause covers all work in connection with the trimming and finishing of slopes both to
embankments and cuttings, the dimensions of which shall be in accordance with the cross-sections
and details shown in the Drawings, or as instructed by the Engineer.
The slopes shall be trimmed by hand or by approved mechanical means to remove loose material and
to provide uniform slopes as described in the Drawings or as instructed by the Engineer. Such
trimming shall be completed prior to construction of the pavement and shall be finished to a uniform
appearance.
Except in solid rock, the tops of all cut slopes shall be rounded unless otherwise directed by the
Engineer. Slopes shall be adjusted, if required by the Engineer, to avoid unnecessary damage or
destruction to standing trees and to harmonise with the existing landscape. The transition to such
adjusted slopes shall be gradual.
Slopes which are flatter than 1 in 4 shall have a standard of finish that can be obtained by a motor
grader.
All loose rocks, stones, and other material shall be removed from the slopes. The final surface of
slopes shall have a rough surface suitable for subsequent grassing; or which will allow the natural
vegetation to grow as described in the Contract.
Performance of work prescribed in this section is not payable directly but shall be considered as a
subsidiary obligation of the Contractor, covered under the contract unit prices for performance of work
under the other payment items of this Series.
(n) Trial Areas

Prior to the commencement of normal working the Contractor shall construct a trial area of not less
2
than 500 m using the materials and equipment proposed for the work to demonstrate compliance with
the requirements of this Clause.
4404 Rock Fill

Rock fill shall be free-draining and well-graded complying with the grading shown in Table 4404/1.
Table 4404/1: Grading Requirements for Rock Fill

Maximum Size % Passing
500 mm 100
200 mm 20 - 75
75 mm 10 - 30
20 mm 5 – 25
2 mm 0
Argillaceous rocks such as clay, shale and marl; and amygdaloidal or vesicular basalts shall not be
used in rock fill. Rock fill shall apply to materials consisting predominantly of hard, durable, angular
rock fragments interspersed with finer material to fill the voids and facilitate mechanical interlock of the
rock. Tabular, flakey or elongated particles shall not be used. If naturally occurring gravel, cobbles
and/or boulders are used then they shall be crushed so that particles have at least one (1) broken
surface.
The material shall be deposited, spread and levelled in layers extending to the full width of the
embankment by a dozer. Each layer shall be compacted by a minimum of eight (8) passes of a
vibrating roller with a static weight of 8 – 10 tonnes.
Rock fill shall not be used in the top 400mm of an embankment.
For rock fill embankment slopes steeper than 1V:1.5H, the outer layer shall comprise hand-placed
interlocking fragments of between 200mm and 500mm dimension.
(a) Constructing Toes for Rock Fill Embankments

Where required, rock fill embankments shall have a toe constructed that is keyed into the underlying
natural ground at the foot of the embankment through the construction of a trench backfilled with
interlocking rock material. The dimensions of the trench shall be as shown on the Drawings, or as
directed by the Engineer; but should be of nominal 2m depth and 5m width.
The toe shall be constructed simultaneously with the rest of the embankment and shall consist of
selected rock material varying in size between 150 mm and 500 mm. If shown on the Drawings, a
layer of synthetic-fibre filter material and a sand blanket shall be installed at the interface between the
rock fill embankment and the toe at the foot of the embankment. Care shall be taken not to damage or
tear such material.
The outer part of the toe shall consist of larger boulders properly bedded by means of smaller
fragments so as to form a stable interlocking surface.
If placing with mechanical construction equipment is impractical, the equipment shall be supplemented
by manual labour to select, bar and place keystones in between the larger boulders until the correct
placing is achieved and the rocks are firmly interlocked.
4405 Side Fill

Side fill is the portion of imported material within the road prism which lies outside the fills, shoulders,
sub-base and base; and is contained within such surface slopes as shown on the Drawings or as
directed by the Engineer.
Construction of side fills for fill-flattening shall be carried out after completion of the fill for the road
prism. The construction of the fill flattening using unsuitable or expansive soil/material as defined in
sub-clause 4103(a) shall be as indicated on the Drawing. In order to minimize the permeability of side
fill and loose flattening of the slope, the Contractor shall remove any boulders, logs, tree stumps and
other perishable materials. The road prism side slope shall be trimmed before placing of the side fill or
fill-flattening material. Attempts to verify density of the materials by processing and compaction are
not required but a compaction mechanism shall be devised by the Contractor and approved by the
Engineer so as to prevent loose fill flattening which could result in ingress of water into the road prism
or erosion of the flattening fill.
If insufficient material for side fills is available, the Contractor shall obtain additional material from ditch
excavations or from nearby pits of similar materials without creating standing water or undermining the
surrounding area all in accordance with the instructions of the Engineer.
The Contractor shall obtain specific approval from the Engineer for processing, supplying and placing
of material for side fill for fill-flattening using material that is unsuitable for other purposes.

When specified in the Contract, the construction of embankment fills shall be measured and paid for in
accordance with the terms set forth. Unless otherwise provided, embankment fills shall not be paid for
directly, but shall be paid under items included in the Contract and prescribed in Divisions 4100 and
4200.
No additional payment will be made for constructing embankments as specified in this Division outside
the restricted areas as defined in Clause 8108.
Sand filter blankets shall be measured and paid for separately.
Item 44.01 Extra over item 42.01 for widening of fills as specified in sub-clause 4403(l)
a) Cut to fill ...........................................................................................................cubic metre (m³)
b) Borrow to fill .....................................................................................................cubic metre (m³)
The unit of measurement shall be the cubic metre of material placed in the widening of existing fills.

The tendered rates shall be paid extra over the rates applicable to normal full width construction, and
shall include full compensation for all additional transport, equipment, labour and supervision;
including any additional costs for the widening of fills; cutting of benches; and widening fills in
restricted areas.
Item 44.02 Extra over item 42.03 for spoiling material excavated from benches constructed
for widening existing fills ................................................................ cubic metre (m³)
The unit of measurement shall be the cubic metre of material excavated from benches in the widening
of existing fills and which is spoiled on the instructions of the Engineer.
The quantity shall be calculated in accordance with the authorised dimensions of the benches.
The tendered rate shall be paid extra over the rates applicable to item 42.03 and shall include full
compensation for all additional costs for spoiling the material; including amongst others, all additional
work, construction equipment, labour and supervision, irrespective of the size and depth of the
benches and the class of material.
No extra-over payment will be made for work in restricted areas.
Item 44.03 Sand fills (as described in sub-clause 4403(j) and 4402(d))
a) Non-plastic sand with up to 20% passing the 0.075mm sieve compacted to100% of modified
AASHTO density .............................................................................................. cubic metre (m³)
b) Non-plastic sand with more than 20% passing the 0.075 mm sieve compacted to 95% of modified
AASHTO density ............................................................................................. cubic metre (m³)
The unit of measurement shall be the cubic metre of sand measured in fills as determined in item
42.01 but with the difference that no distinction shall be made between different layer thicknesses in
which the material is placed and compacted.
The tendered rates shall include full compensation for procuring, transporting, placing, spreading,
levelling, compacting and trimming the sand.
Item 44.04 Rock Fill, Pioneer Layers and Sand Filter Blankets
a) Rock fill............................................................................................................. cubic metre (m³)
b) Toes for rock fill embankments ........................................................................ cubic metre (m³)
c) Pioneer layer .................................................................................................... cubic metre (m³)
d) Sand filter blanket ............................................................................................ cubic metre (m³)
The unit of measurement shall be the cubic metre of material measured in the compacted layer.
For sub-item (a), the quantity measured shall be calculated by the method of average end areas from
levelled cross-sections prepared from the ground line after clearing and grubbing, the removal of
topsoil and the completion of any preparatory roadbed treatment which may have been ordered by the
Engineer; but prior to the construction of the fill; and the final specified or authorised fill cross-section
superimposed thereon at 20m intervals along the centreline of the road.
All measurement shall be neat, and that part of the layer placed in excess of the authorised cross-
section shown on the Drawings or directed by the Engineer, will not be paid for irrespective of the
tolerances in workmanship allowed under the contract. Where the roadbed has subsided under the
rock fill, the quantities shall be adjusted to make allowance for such subsidence, as set out in sub-
clause 4209(a)(i).

Measurement and payment of sub-item (a) shall distinguish between the type and source of fill and the
minimum compaction density related to the depth of the layer within the fill as specified on the
Drawings or as instructed by the Engineer.
The quantities for sub-items (b) and (d) shall be calculated from the authorised dimensions.
For sub-item (c) the compacted volume of the material in the pioneer layer may be taken as equal to
70% of the loose volume of the material in the trucks as an alternative to taking cross-sections before
and after construction.
The tendered rates shall include full compensation for procuring, furnishing, transporting and placing
the material, including excavating as if in common (normal or soft) excavation; the removal of
overburden in borrow areas; the cutting of benches; for preparing, processing, shaping, watering,
mixing, and compacting the materials to the densities required on the Drawings or in the manner
specified herein; forming, trimming and finishing all slopes; replacing materials rendered unsuitable
with suitable material as approved by the Engineer; selection and separation of materials; taking
precautions to avoid damage to property; and for removal and disposal of oversize or surplus material
from the road after processing, including all transport.
The tendered rates shall also include full compensation for the supply and installation of synthetic-fibre
filter material where specified or indicated on the Drawings.
Item 44.05 Side fills or Fill-flattening................................................................... cubic metre (m³)

The unit of measurement shall be the cubic metre of side fill or fill-flattening constructed (using
materials from excavations or borrow areas that would otherwise be classified as unsuitable for use in
the works) as shown on the Drawings or as instructed by the Engineer.
The tendered rates shall include full compensation for procuring, transporting, placing, spreading,
levelling, compacting and trimming the material.

Division 4500: Material Stabilisation
4501 Scope
This section covers the stabilisation of materials used in the construction of the roadbed and/or
subgrade; sub-base and road base (covered in Series 5000); by the addition of a chemical stabilising
agent; or by the mechanical modification of the material by mixing various materials; or by treating the
material with a bituminous stabilising agent. It includes the furnishing, spreading and mixing-in of the
stabilising agent or soil binder. In the case of chemically stabilised materials the layer is also given a
curing treatment.
4502 Materials
(a) Material to be Stabilised

Material to be stabilised shall be any naturally occurring cohesive or non-cohesive soil or processed
material, the properties of which can be permanently improved by the process of stabilisation to
comply with the requirements of this Specification for the relevant materials for road bed and/or
subgrade, sub-base and road base.
Materials considered for stabilisation shall have a minimum grading coefficient of uniformity of 5.
(i) Road Bed and/or Subgrade Stabilisation

Road bed and/or subgrade materials shall be considered for stabilisation under the following
circumstances:
 To establish a dryer construction platform in wet soils to facilitate the compaction of the upper
layers. In this situation the stabilised subgrade material is not usually considered as a
structural layer of the pavement.
 To strengthen a weak soil and restrict the volume change potential of a highly plastic
(expansive) or compressible soil. In this case the modified soil shall provide a structural
component to the pavement.
The thickness, depth or zone of the roadbed or subgrade that shall be selected for material
stabilisation/improvement shall be as shown on the Drawings or as indicated by the Engineer. Where a
thin zone or short length of road bed or subgrade is subject to improvement, removal and replacement
shall be the preferred alternative unless a suitable replacement soil is not economically available.
(ii) Stabilised Sub-base and Road Base Material

The stabilisation of materials for use as sub-base and road base shall provide a permanent
improvement to the unstabilised materials to meet the requirements of Series 5000 of these
Specifications.
(b) Stabilising Agents

The stabilising agent shall be either one or more of the following agents specified on the Drawings, in
the Bill of Quantities; or in the Particular Specifications; or ordered by the Engineer.
(i) Ordinary Portland Cement

Portland cement shall comply with the requirements of AASHTO M-85, Type II or the equivalent ISO
standard class.
The use of rapid-hardening Portland cement will not be permitted unless approved by the Engineer.

(ii) Portland Blast-Furnace Cement

Portland blast-furnace cement shall comply with the requirements of BS 146 or SABS 626.
(iii) Lime
Lime shall comply with the requirements of AASHTO M-216.
The use of unslaked lime will not be permitted.
(iv) Other Chemical Stabilising Agents

Other chemical stabilising agents such as fly-ash; cement/lime-slag mixtures using ground granulated
blast-furnace slag; and Portland fly-ash cement may be used if specified in the Particular
Specifications or if approved and so instructed by the Engineer. The relevant ASTM, BS or SABS
specification for the particular product shall be used in assessing the suitability of the stabilising agent
for use in the works.
(v) Soil Binder

Soil binder for mechanical modification shall be taken from within the limits of an approved source and
shall be subject to such requirements regarding grading, plasticity index or other properties, given in
Series 5000 or as may be indicated on the borrow pit plans, or prescribed by the Engineer.
(vi) Bituminous Stabilising Agents

The bituminous stabilising agent shall be one of the following agents as specified on the Drawings, in
the Bill of Quantities or in the Particular Specifications; or as may be instructed by the Engineer, and
shall comply with the appropriate AASHTO specification given below:
 Stable-grade bituminous emulsion: (60% net bitumen) to AASHTO M-140 (anionic) or

AASHTO M-208 (cationic)
(vii) Fillers for Bitumen Stabilisation

Fillers such as lime or Ordinary Portland Cement added for improving adhesion and/or stability of
bitumen used for stabilisation shall comply with the requirements of sub-clause 4502(b).
(viii) Aggregate for Bitumen Stabilisation

Material for bituminous stabilisation shall be subject to the requirements prescribed for chemically
stabilised gravel or crushed-stone base, with the provision that the plasticity index shall not exceed 6
after the addition of chemical stabilising agent (if required) and before bitumen stabilisation.
In the case of naturally occurring gravel material, the percentage of material smaller than 0.075mm
shall not exceed 12%.
Where naturally occurring gravel material or crushed stone has been recovered from existing
pavements, the Engineer may allow up to 15% material smaller than 0.075 mm to be present in
material intended for bituminous stabilisation.
Where specified in the Particular Specifications, material from existing pavements mixed with existing
bituminous surfacing material may be used in a bituminous stabilised base where so approved by the
Engineer in writing. However, the material from an existing surfacing shall not be more than 30% by
volume, and no fragment shall be more than 35 mm in size.
(ix) General
From the time of purchase to the time of use, all stabilising agents shall be kept under proper cover
and protected from moisture.
Consignments of these materials shall be used in the same sequence as they are delivered to the
Works. Stocks, which may have been stored on site for longer periods than three (3) months, shall not
be used in the Works, unless otherwise authorised by the Engineer.

4503 Chemical Stabilisation
(a) Preparation of Layer

The material to be stabilised using stabilisers as described in sub-clause 4502(b)(i), (ii), (iii) and (iv)
shall be prepared and placed as specified in the respective Divisions for subgrade, sub-base and road
base.
(b) Application of Stabilising Agent

After preparation of the layer of soil or gravel, the stabilising agent shall be spread uniformly over the
full width of the layer by means of an approved type of mechanical spreader at the prescribed rate of
application in a continuous operation, or it may be spread by hand.
When spreading is done by hand, pockets or bags of stabilising agent shall be accurately spaced at
equal intervals along the section to be stabilised so as to provide the specified rate of application. The
bags shall be opened, the stabilising agent spread in transverse rows across the full specified width of
stabilisation and the empty bags removed. Such spreading shall be done as evenly as possible and
uniform distribution of the stabilising agent over the entire surface to be treated shall then be obtained
by levelling-off the rows of stabilising agent by means of hand rakes and/or screeds.
The Engineer may permit the spreading of the hand-spotted stabilising agent by means of a motor
grader provided that an even distribution of stabilising agent is obtained.
(c) Mixing in of Stabilising Agent

Immediately after the stabilising agent has been spread, it shall be thoroughly mixed with the material
for the full depth of treatment. Care shall be exercised not to disturb the underlying compacted layer,
nor to mix the agent below the desired depth. Mixing shall be continued and repeated as often as may
be required to ensure a uniform mix of the soil or gravel and stabilising agent over the full width and
depth of material to be treated and until the resulting mixture is homogeneous and of uniform
appearance throughout. Mixing should be completed as quickly as possible.
Mixing shall be done by grader, disc harrow, rotary mixer or equivalent plant working over the full area
and depth of the layer to be stabilised, by means of successive passes of the equipment.
Mixing may also be done in central batch-mixing plants, but the Contractor will not be entitled to
payment for incidentals resulting from such procedure.
(d) Watering
Immediately after the stabilising agent has been properly mixed with the material, the moisture content
of the mixture shall be determined and the required amount of water added. The amount of water to be
added shall be sufficient to bring the mixed material to the optimum moisture content for the
compaction equipment used and the minimum density required in the respective Divisions for sub
grade, sub-bases and bases.
Each application or increment of water shall be well mixed with the material so as to avoid
concentration of water near the surface or flow of water over the surface of the layer.
Particular care shall be exercised to ensure uniform and satisfactory moisture distribution over the full
depth, width and length of the section being stabilised and to prevent any portion of the work from
getting excessively wet after the stabilising agent has been added. Any portion of the work that
becomes too wet after the stabilising agent has been added and before the mixture has been
compacted will be rejected and such portions shall be scarified, re-stabilised, re-compacted and again

finished off in accordance with the requirements herein specified, all at the expense of the Contractor
and to the satisfaction of the Engineer.
The water supply and watering equipment shall be adequate to ensure that all water required is added
and mixed with the material being treated within a short enough period to enable compaction and
finishing to be completed within the period specified in sub-clause 4503(h).
(e) Compaction
The Compaction provisions of the respective Divisions for sub grade, sub-bases and bases shall
apply.
During compaction, loss of moisture through evaporation shall be corrected by further light
applications of water. At the completion of the primary compaction, the surface shall be cut to the
finished level and all cuttings removed from the surface before final rolling.
Final rolling shall be done with equipment that will give a smooth surface conforming to the surface
tolerance specified. The minimum compaction requirements shall be as specified for the particular
layer in the various Divisions of these Specifications.
A sufficient number of compacting units shall be employed on the work to ensure that from the time the
stabilising agent is first applied to the layer, the process of mixing, applying water, compaction,
shaping and final finishing, is completed within the periods specified in sub-clause 4503(h).
Vibrating rollers will only be used with the written approval of the Engineer.
(f) Turning Areas and Joints with Completed Work

Any completed section of the stabilised layer adjacent to new stabilisation work; and which is used as
a turning area by equipment in constructing the adjoining section; shall be provided with a protective
cover of soil or gravel at least 100 mm in thickness over a sufficient length to prevent damage to work
already completed.
At the time of final finishing of the adjoining section, such cover shall be removed to permit the
construction of a smooth joint at the junction of the different sections.
Material in the vicinity of the joint, which cannot be processed satisfactorily with normal construction
equipment, shall be mixed and compacted by hand or with suitable hand-operated equipment.
(g) Curing of Stabilised Work

The stabilised layer shall be protected against rapid drying out for at least seven (7) days following
completion of the layer.
The methods of protection may be any of the following:
1) Immediately following completion, the stabilised layer shall be kept continuously wet or damp
by spraying with water at frequent intervals. This method will be permitted for up to a maximum period
of 24 hours after which time one of the methods (2), (3), or (4) shall be applied. The Contractor is
warned that the Engineer in his sole discretion may reject work that is not kept continuously wet or
damp and is subjected to wet-dry cycles that are detrimental to the curing of the layer.
2) The stabilised layer shall be covered with the material required for the layer on top thereof
while the stabilised layer is still in a wet or damp condition. The material for the next layer and forming
the protective layer to the stabilised layer shall be watered at such intervals as may be required to
keep the stabilised layer continuously wet or damp. In dry weather this shall be done at least once in
every 24 hours.

3) The stabilised layer shall be covered with an approved curing membrane applied at the rate
4) Where bituminous surfacing is specified on top of the stabilised base or sub-base, the prime or
tack coat together with the first application of bituminous surfacing may be utilized as a curing
membrane and shall be applied as specified in Division 6100 and 6200 of these Specifications.
5) The stabilised layer shall be kept continuously wet for seven (7) days by an effective fog-
spraying system that will not damage the surface of the layer or by any other system approved by the
Engineer. During this period the application of water shall be so controlled that it will not unduly wet the
layer but at the same time will not allow the layer to dry out. Layers allowed to dry out may be rejected
if damaged thereby. In regard to this method payment will be made only for the application of water.
No additional payment will be made for curing as described above except that the application of a
curing membrane or water in accordance with method (5) will be paid for when the application of such
methods has been ordered by the Engineer.
(h) Construction Limitations

The stabilising agent shall only be applied to such an area that all processing, watering, compacting
and finishing can be completed within the period stated in Table 4503/1:
Table 4503/1: Maximum time for completion in stabilisation

Maximum time for completion
after stabilising agent comes
Stabilising Agent
into contact with the material to
be stabilised.
Ordinary Portland cement,
and/or approved Portland 8 hours
cement blends
Lime 10 hours
No stabilising agent shall be applied when the moisture content of the material to be stabilised
exceeds the optimum moisture content for the compaction equipment proposed, by more than 2% of
the dry mass of the materials.
No stabilisation shall be done during wet weather or when, in the opinion of the Engineer, windy
conditions may adversely affect the stabilising operations.
Any rain falling on the working area during the process of stabilisation may be sufficient cause for the
Engineer to order such areas as are affected to be reconstructed at the Contractor’s own cost.
No traffic or any equipment not actually used in the processing of the layer shall be allowed to pass
over the freshly spread stabilising agent.
Only equipment required for curing or priming shall be allowed over the treated layers during the
specified curing period.
4504 Mechanical Modification

Mechanical modification shall consist of the addition of an approved soil binder to material to improve
its properties, or the mixing of material originating from various sources, as described hereafter.

(a) Modifying Soil and Gravel by the Addition of a Soil Binder

This process involves the addition and mixing of an approved soil binder as specified in Sub-
clause 4502(b)(v), which shall not exceed 20% by mass of the total mixture, to the material to be
improved.
The material to be treated shall be prepared and spread to the required loose thickness as specified in
the respective Divisions for sub grade, sub-bases and bases.
An approved binder material shall then be spread over the prepared material at the required rate, and
the materials shall be mixed by a suitable method (eg motor grader, disc harrow and/or other suitable
plant approved by the Engineer) until the binder material is uniformly mixed with the material being
treated.
The mixed materials shall then be watered, mixed and compacted as described in the respective
Divisions for roadbed and/or subgrade, sub-bases and bases.
(b) Mixing Materials from Various Sources

The mixing of materials from various sources requires the material from the first source to be dumped
onto the road, prepared, broken down and spread in a layer of uniform thickness, after which it is
lightly rolled with a steel-wheeled roller.
The material from the second source shall then be dumped onto the road, prepared, broken down and
evenly spread across the first layer, following which, the two materials shall be thoroughly mixed.
The mixing of materials from different sources will apply only when the smallest component of the
mixture exceeds 20% of the total mass of the mixture. If not, the process will be regarded as the
addition of a soil binder as described above in sub-clause (a).
(c) Recombining Recovered Material

Where specified in the Particular Specifications or required by the Engineer, recovered material shall
be recombined to comply with the requirements of the layer for which it is proposed for use.
4505 Bituminous Stabilisation

In terms of these Specifications, bitumen stabilisation shall be confined to the stabilisation of materials
using bitumen emulsion as specified in sub-clause 4502(b)(vi).
Foam-bitumen stabilisation shall be covered in the Particular Specifications as required.
(a) Preparing the Material

The material to be stabilised shall be prepared and placed as specified in the respective Divisions for
sub grade, sub-bases and bases, and shall be ploughed into furrows.
The moisture content of the material shall be just below the optimum moisture content during mixing-in
of the stabilising agent. Immediately before the stabilising agent is applied, the material shall again be
lightly wetted. No dry material whatsoever may then be present.
(b) Mixing in of Active Filler

Where an active filler (lime or cement) has been specified in line with sub-clause 4502(b)(i), (ii) and
(iii), or if so required by the Engineer, to assist the extraction of water from the bitumen emulsion to
facilitate the breaking of the emulsion, it shall first be spread and mixed in as described in sub-clause
4503(c) prior to the addition of the bitumen emulsion. Separate payment will be made for providing,
applying and mixing-in the active filler.

(c) Heating and Diluting the Bituminous Stabilising Agent

The bituminous stabilising agent shall be heated as specified in Division 6300. During dilution of the
bituminous emulsion with water, care shall be taken to prevent its breaking. This will mean that clean
water shall be added gradually during constant stirring of the emulsion or its circulation by pumps.
(d) Applying the Stabilising Agent

After preparing the material, the stabilising agent shall be uniformly applied by an approved binder
distributor in a continuous process at the prescribed rate of application over the full area of the layer.
Multiple applications may be necessary. In such cases it shall be necessary to ensure that the
moisture escaping on account of drying out is replaced by water being applied. Care shall be taken not
to allow the stabilising agent to run from the layer before it has been mixed in.
The stabilising agent shall be diluted with water to obtain a better distribution. However, this should not
affect the net bitumen specified to be mixed into the material for effective stabilisation.
In cases where, in the opinion of the Engineer, it is impracticable to apply the stabilising agent by
mechanical binder distributor, hand distributors may be used.
Where so required by the Engineer, a certain part (not more than 10% of the total quantity) of the
stabilising agent shall be sprayed onto the surface in a diluted form (with a maximum of 2 parts of
water to 1 part of bituminous stabilising agent) immediately, before the final finishing of the layer.
The stabilising agent shall, immediately after each application, be mixed with the loose material, to the
full depth of the treated layer. This work shall be done carefully so as not to disturb the underlying
compacted layer and as not to mix in the stabilising agent deeper than the required depth.
During mixing-in, the moisture content of the material shall be immediately below or at optimum
moisture content.
Mixing shall continue for as long as may be necessary, and shall be repeated as frequently as may be
necessary to ensure the thorough and uniform mixing of the gravel or aggregate and the stabilising
agent over the full surface and depth of the material to be treated, until the resulting mixture is
homogeneous and has the same appearance throughout, without any individual spots of the
stabilising agent being visible; and until the mixture has reached the required moisture content for
compaction.
Mixing shall be done by road grader, disc harrow, rotary mixer or similar plant, which will work the layer
to be stabilised by way of successive passes over its full surface and depth.
Mixing may also be done in a central batch-mixing plant, but the Contractor shall not be entitled to
payment for other costs arising from this method of work.
(e) Compaction
The provisions of sub-clause 4503(e) shall apply.
The moisture content during the compaction of stabilised layers shall not exceed the optimum of the
gravel or aggregate. However, the Engineer may amend the required moisture content.
Where the required densities for a pavement layer in accordance with modified AASHTO density is
specified, the field densities shall be determined on the material as obtained from the road, and the
field densities shall not be adjusted on account of the presence of bituminous stabilising agents.

(f) Turning Areas and Joints with Completed Work

The turning areas and joint with completed sections shall be finished in accordance with sub-clause
4503(f) for obtaining an even and well-compacted joint and so as not to cause damage to the adjacent
parts of completed sections.
(g) Construction Limitations

When gravel is being stabilised with a bituminous emulsion, the layer shall be mixed and compacted
within 24 hours.
Limited slushing shall be done within 48 hours.
Where crushed stone is stabilised with bituminous emulsion and used for repairing sub-base or base
layers, it shall be mixed in, placed, and compacted within 5 hours.
4506 Construction Tolerances
(a) Rate of Application

The average rate of application of chemical stabilising agents, when applied by mechanical bulk
spreading equipment and measured by the “canvas patch” or “tray” method, shall be equal to the
specified rate of application ± 5% measured over any section not exceeding 1.0 km in length and no
single measurement shall show a value of more than 20% below the specified rate.
When hand-spotted, stabilising agents shall be spread exactly to the specified rate of application.
(b) Uniformity of Mix

The cementitious binder content (lime or cement) of the mixed material as determined on 50 samples
per lot when sampled and tested as specified by the Engineer, shall be within the following limits:
 The average cementitious binder content of all 50 samples shall not be less than 95% of the
specified binder content.
 Not more than 9 samples out of the 50 shall show a cementitious binder content lower than
70% of the specified binder content.
The test results shall be adjusted to allow for the presence, in the material to be stabilised, of minerals
that affect the test results. The above requirements for uniformity of mix shall only be applied provided
that the variation in these adjustments is within the specified limits.
4507 Construction of Trial Section

Prior to the construction of stabilised layers, the Contractor shall demonstrate by constructing a trial
section that the equipment and procedure he proposes to use will result in the construction of the
layers in accordance with these Specifications.
2
The trial section shall be at least 2 000m in area and shall be constructed in its required position in the
pavement. Only when such a trial section has been satisfactorily constructed and accepted by the
Engineer shall the Contractor be permitted to proceed with the stabilised layer in the permanent work.
In the event of the trial section being unsuccessful, the Contractor shall remove the trial section should
the Engineer so require.
The trial section shall be paid for separately only when it complies with all the requirements of these
Specifications and has been approved by the Engineer.
After approval has been obtained, the mixing process and equipment shall remain unaltered unless
otherwise approved by the Engineer.

4508 Stabilisation Work in Restricted Areas
(a) General Requirements

Suitable equipment and methods acceptable to the Engineer shall be used in restricted areas so that
the required densities will be met throughout the thickness of the layer. If necessary, the layers shall
be placed in thicknesses, which are less than the specified layer thickness.
Where existing and new work are joined (longitudinal joints, and others) material shall be satisfactorily
mixed and compacted without any permeable or loose patches.
With regard to the curing of stabilised layers in restricted areas, the construction of the subsequent
layers shall be commenced as soon as practicable with the permission of the Engineer.
(b) Chemical Stabilisation

Where pavement layers are to be widened no chemical stabilising agent may be spread or mixed
beyond the required width.
The Contractor will not be permitted to mix material for stabilisation on adjacent surfaces unless prior
permission has been obtained from the Engineer in writing.
Where the existing surfaces of the road may not be used for this purpose the Contractor shall apply
other approved methods of mixing.
Payment over and above payment for work in restricted areas will not be considered for other costs
arising from this manner of mixing or working.
(c) Bituminous Stabilisation

No mixing of material with bituminous stabilising agent will be permitted on the existing surfacing
without the written permission of the Engineer, and then only where such surface is required to be
resealed or provided with a resurfacing layer.
Where restricted areas are such that mixing in these areas will not be practicable and/or mixing on
adjacent surfaces is not permitted, mixing shall be done in a central mixing plant. In the case of
smaller quantities, approved concrete mixers may be used.
Payment over and above payment for work in restricted areas will not be considered for other costs
arising from this manner of mixing or working.
4509 Quality Control
(a) Process Control
(i) Stabilising Agent

The Contractor shall keep detailed records of the quantities of stabilising agent applied to the road and
the volumes of material stabilised, and make these records available to the Engineer.
The Contractor shall also monitor the rate of application when using bulk-spreading equipment by
taking a canvas patch or tray every 200 m, unless, with the Engineer’s permission, this may be
reduced.
When using a bulk spreader on site for the first time or after it has been adjusted or repaired, the
spread rate shall be checked by at least five (5) tests over as short a distance as is practicable with
the equipment running at normal speed without stops. Spreading shall not continue on a large scale
until the spread rate is within allowable tolerances.

(ii) Compaction
The requirements for process control in respect of compaction shall be the same as stated for the
unstabilised layers in relevant Divisions. Densities shall be determined as described in AASHTO T-80.
Unless noted otherwise the top 600 mm of embankment fill shall be compacted to 95% of modified
AASHTO maximum density, as determined by the test method AASHTO T-80. All material below the
top 600 mm shall be compacted to 90% of the maximum dry density.
(b) Routine Inspection and Testing

Routine inspections will be carried out by the Engineer to test the quality of materials and
workmanship for compliance with the requirements of this Division.
Compliance with the requirements for the compaction of stabilised materials shall be as specified in
the relevant section for each layer.
The requirements for uniformity of mix and rate of application shall be deemed to have been complied
with if the mixture meets with the requirements of Clause 4506.
When the tests for uniformity of mix are not applicable as stated in sub-clause 4506(b), the material
shall be visually appraised for uniformity of mix.
(c) Defective Work or Materials

Any materials or work which do not comply with the requirements specified, shall be removed and
replaced with new materials or work complying with the specified requirements
OR
If the Engineer permits, shall be repaired as specified in Clause 1208, so that after being repaired it
will comply with the specified requirements.
4510 Other Stabilisers

All other stabilisers not specified in sub-clause 4502(b), including proprietary-brand stabilisers shall be
included in Particular Specifications or as instructed by the Engineer. Trial sections shall be
constructed as specified in Clause 4507.

Items 45.09, 45.10 and 45.11 are applicable solely to stabilisation work that has to be executed in a
restricted area of which the width is less than 3m or the length is less than 150m.
Item 45.01 Chemical stabilisation (layer thickness indicated) extra over unstabilised
compacted layers (layer to be stabilised indicated) ..........................cubic metre (m³)
The unit of measurement shall be the cubic metre of stabilised material, the quantity of which shall be
determined in accordance with the authorised dimensions of the layers treated as instructed by the
Engineer.
The tendered rates for chemical stabilisation shall be paid as extra over the rates tendered for
constructing the unstabilised layers.
The tendered rates shall include full compensation for spreading and mixing the stabilising agent;
curing the stabilised sections; any extra watering required; and all materials, supervision, labour, plant,
equipment, tools and incidentals (extra over those provided for in the rates tendered for constructing
the unstabilised layer) necessary for completing the specified work; but excluding the cost of supplying
the stabilising agent. No distinction will be made in respect of the type of stabilising agent used; the
time for completion or the specific layer being stabilised; and the extra over rate tendered shall apply
to any combination thereof. The Engineer reserves the right to vary the thickness of the layer to be
stabilised by up to 20mm, and the contract rate for this work shall not be amended by such change.
Item 45.02 Chemical stabilising agent

a) Ordinary Portland cement. .......................................................................................... .tonne (t)
b) Portland blast-furnace cement ..................................................................................... .tonne (t)
c) Lime (type indicated). .................................................................................................... tonne (t)
d) Other chemical stabilising agents (type specified)........................................................ tonne (t)
The unit of measurement shall be the tonne of chemical stabilising agent specified in sub-clause
4502(b) but excluding other chemical stabilisers, including proprietary brand stabilisers that shall only
be considered in Particular Specifications. Measurement shall distinguish between the various
chemical stabilising agents used. When mixtures of cement or lime are used, the quantity of each
constituent shall be measured separately and not the mixture as a whole.
The quantity will be determined in accordance with the authorised rate of application.
The tendered rates shall include full compensation for providing the stabilising agent at the works,
irrespective of the rate of application specified or ordered by the Engineer; but shall make allowance
for the differences in mixing, compaction and curing times specified for the various stabilising agents.
Item 45.03 Mechanical modification (extra over untreated layer)

a) By adding a soil binder .................................................................................... cubic metre (m³)
b) By mixing materials from different sources .................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of compacted material that has been mechanically
modified as specified in Clause 4504, and the quantity shall be calculated in accordance with the
authorised dimensions of the mechanically modified layer.
The tendered rates for mechanical modification shall be paid as extra over the rate for the construction
of an untreated layer and shall include full compensation for all labour, plant, tools, transport and other
incidentals necessary for supplying and hauling the material; and for spreading the soil binder and
mixing it with the material to be treated, or for mixing materials from different sources as specified.
The addition of material during a crushing or screening process, whether it is specially imported
material, which is not the product of the crushing process; or whether it is crushed material screened
out and then replaced in part or as a whole; will not be regarded as treatment with soil binder for
measurement and payment purposes; but will be regarded as part of the process of producing crushed
stone for sub-base, base or other construction work. The cost of which shall be included in the
tendered rates for those items of work.
Item 45.04 Bituminous stabilisation (extra over the untreated layer) .............. cubic metre (m³)
The unit of measurement shall be the cubic metre of material stabilised. The quantity shall be
determined in accordance with the authorised dimensions of the completed layer.
The tendered rate for bituminous stabilisation shall be paid extra over the rates for constructing the
untreated layer and shall include full compensation for all incidentals, excepting the compensation
covered by items 45.07 and 45.08, which are necessary for treating the material as specified. No
distinction shall be made with regard to the type of bituminous stabiliser used, the time for completion,
and the particular layer to be stabilised; and the tendered extra rate shall apply to any combination
thereof. The Engineer reserves the right to alter the thickness of the layer to be stabilised, and the
contract rates will remain applicable to all layer thicknesses between the limits of 100 mm and
200 mm.
Item 45.05 Provision and application of water for curing. ........................................ kilolitre (kℓ)
The unit of measurement shall be the kilolitre of water provided and applied in accordance with the
Engineer’s instructions for curing the stabilised layer as specified in sub-clause 4503(g).
The tendered rate shall include full compensation for furnishing, transporting and applying the water
and for the provision of spraying equipment. Water applied within the first 24 hours of completion of
the stabilised layer will not be calculated for payment.
Item 45.06 Curing by covering with the subsequent layer ........................... .square metre (m²)
The unit of measurement shall be the square metre of stabilised layer being cured by covering with the
subsequent layer as specified in sub-clause 4503(g). The quantity will be determined by the
authorised dimensions of the layer to be treated.
The tendered rate shall include full compensation for incidentals in respect of transporting and
applying the subsequent layer for curing as specified; including the cost of regularly supplying and
applying water.
Item 45.07 Bituminous stabilising agent

a) Anionic stable grade bituminous emulsion (60% net bitumen) ........................................litre (ℓ)
b) Cationic stable grade bituminous emulsion (60% net bitumen) ......................................litre (ℓ)
c) Other (specify). .................................................................................................................litre (ℓ)
The unit of measurement shall be the litre of bituminous stabilising agent applied on the instruction of
the Engineer.
The tendered rates shall include full compensation for providing, diluting and applying the stabilising
agent, irrespective of the prescribed rate of application.
Item 45.08 Additives for bituminous stabilisation

a) Ordinary Portland cement ........................................................................................... tonne (t)
b) Lime ............................................................................................................................ tonne (t)
The unit of measurement shall be the tonne of additive applied on the Instruction of the Engineer.
The tendered rates shall include full compensation for providing and spreading the additive and for the
incidentals required for mixing it in. The tendered rates shall apply irrespective of the percentage of
additive prescribed between the limits of 0.5% and 1.5% by mass.
Item 45.09 Extra over item 45.01 for chemical stabilisation in restricted areas
a) Mixing in mechanical mixers. ............................................................................cubic metre (m³)
b) In-situ mixing. ....................................................................................................cubic metre (m³)
c) Mixing as for in-situ mixing but on adjacent surfaces. ......................................cubic metre (m³)
Item 45.10 Extra over item 45.03 for mechanical modification in restricted areas
a) Mixing in mechanical mixers ............................................................................cubic metre (m³)
b) In-situ mixing ................................................................................................... cubic metre (m³)

c) Mixing as for in-situ mixing but on adjacent surfaces ...................................... cubic metre (m³)
Item 45.11 Extra over item 45.06 for bituminous stabilisation in restricted areas
a) Mixing in mechanical mixers. ........................................................................... cubic metre (m³)
b) In-situ mixing. ................................................................................................... cubic metre (m³)
c) Mixing as for in-situ mixing but on adjacent surfaces ...................................... cubic metre (m³)
The unit of measurement shall be a cubic metre of chemically stabilised (item 45.09) or modified
material; mechanically modified material (item 45.10); or bituminous stabilised material (item 45.11) in
restricted areas measured in place after placement irrespective of the layer treated. Payment shall
apply only to bases, sub-bases and selected sub-grade/capping layers.
The tendered rates shall include full compensation for all additional costs for executing the work in
restricted areas, and shall amongst others include full compensation for the additional costs for
applying stabilising agents or soil binders in restricted areas, as well as for curing chemically stabilised
layers in restricted areas (irrespective of the method of curing), and the application of additives for
bituminous stabilisation in restricted areas.
Payment under item 45.09 will not distinguish between the various types of chemical stabilising
agents.
Payment under item 45.10 will not distinguish between the addition of soil binder and the mixing of
material from various sources.
Payment under item 45.11 will not distinguish between the various types of bituminous stabilising
agents or various types of additives.
Item 45.12 Extra over items 45.01 45.03 and 45.04 for trial sections ................... cubic metre (m³)
The unit of measurement shall be the cubic metre of compacted stabilised layer that has been placed
as a trial section and approved by the Engineer.
The tendered rate shall include full compensation for all additional work, testing and incidentals
associated with the construction of an approved trial section as specified. It shall also include full
compensation for trial sections removed as excess/unsatisfactory material.

Series 5000: Sub-Base, Road Base and Gravel Wearing

Course
TABLE OF CONTENTS
DIVISION 5100: SUB-BASES ................................................................................................................. 276
5101 Scope ........................................................................................................................................ 276
5102 Materials ................................................................................................................................... 276
5103 Material Sources for Sub-Bases ............................................................................................... 276
5104 Material Requirements Sub-Base............................................................................................. 276
(a) General .......................................................................................................................................... 276
(b) Particle Size Distribution and Shape ............................................................................................. 276
(c) Plasticity........................................................................................................................................ 277
(d) Density and Strength ..................................................................................................................... 277
(e) Use of Laterite as Sub-base ........................................................................................................... 278
(f) Sub-base Materials for Low Volume Roads .................................................................................. 278
5105 Construction Requirements ...................................................................................................... 278
(a) General .......................................................................................................................................... 278
(b) Stabilisation .................................................................................................................................. 278
(c) Trial Areas ..................................................................................................................................... 279
(d) Traffic on Sub-base ....................................................................................................................... 279
(e) Existing Pavement Layers ............................................................................................................. 279
5106 Construction Requirements for Sub-Bases Using Recycled (In-Situ) Pavement Material ....... 279
(a) General .......................................................................................................................................... 279
(b) Milling/Scarifying ......................................................................................................................... 279
(c) Placing, Spreading and Compacting ............................................................................................. 279
5107 Protection and Maintenance ..................................................................................................... 279
5108 Sub-Base as a Filter or Separating Layer ................................................................................ 280
(a) Levels ............................................................................................................................................ 280
(b) Width............................................................................................................................................. 280
(c) Thickness ...................................................................................................................................... 280
(d) Cross Section ................................................................................................................................ 280
5110 Testing ...................................................................................................................................... 281

(b) Routine Inspection and Testing .....................................................................................................281
DIVISION 5200: ROAD BASES (EXCLUDING BITUMINOUS BASES) ............................................................. 285
5201 Scope ........................................................................................................................................ 285
5202 Dimensions ............................................................................................................................... 285
5203 Materials.................................................................................................................................... 285
(a) Sources of Material ....................................................................................................................... 285
(b) Road Base Material Types .............................................................................................................285
5204 Material Requirements for Crushed Stone ............................................................................... 285
(a) General ..........................................................................................................................................285
(c) Plasticity Index .............................................................................................................................. 286
(d) Density, Strength and Durability ...................................................................................................286
(e) Soluble Salts (< 6.7 mm fraction) .................................................................................................287
5205 Material Requirements for Natural Gravels .............................................................................. 287
(a) General ..........................................................................................................................................287
(c) Plasticity Index .............................................................................................................................. 288
(d) Density, Strength and Durability ...................................................................................................288
(e) Chemically Stabilised Natural Gravel Base ..................................................................................289
(f) Soluble Salts ..................................................................................................................................290
(i) Untreated material ..................................................................................................................................... 290
(ii) Material to be stabilised with lime or cement ........................................................................................... 290
(g) Natural Gravels Base for Low Volume Roads ...............................................................................290
(i) Lateritic road base gravels ........................................................................................................................ 292
(ii) Basic Igneous Rock (including Basaltic and Doleritic Gravels) for Road Base Gravels .......................... 292
(iii) Cinder gravels ........................................................................................................................................... 292
5206 Material Requirements for Dense Bitumen Macadam Base ..................................................... 292
5207 General Construction Requirements ........................................................................................ 293
5208 Construction Requirements for Crushed Stone Base ............................................................... 293
(a) Equipment .....................................................................................................................................293
(b) Trial Section and Other Requirements Prior to Construction of the Crushed Stone Base .............293
(c) Placing and Compaction ................................................................................................................294

(d) Watering and Slushing .................................................................................................................. 295
(i) Continuous Process ................................................................................................................................... 295
(ii) Multi-stage Process (water or slurry rolling) ............................................................................................ 295
(e) Stabilisation .................................................................................................................................. 296
(f) Traffic on Road base ..................................................................................................................... 296
5209 Construction Requirements for Natural Gravel Road Base ..................................................... 296
(a) Equipment ..................................................................................................................................... 296
(b) Placing and Compaction ............................................................................................................... 296
(c) Stabilisation .................................................................................................................................. 297
(d) Trial Sections ................................................................................................................................ 297
(e) Traffic on Road Base .................................................................................................................... 297
5210 Construction Requirements for Dense Bitumen Macadam Road Base ................................... 297
(b) Surface level.................................................................................................................................. 298
(c) Layer thickness ............................................................................................................................. 298
(d) Width............................................................................................................................................. 298
(e) Cross Section ................................................................................................................................ 298
DIVISION 5300: BREAKING UP EXISTING PAVEMENT LAYERS .................................................................. 303
5301 Scope ........................................................................................................................................ 303
5302 Selecting the Material ............................................................................................................... 303
5303 Classifying the Material ............................................................................................................ 303
(a) Existing Bituminous Material ....................................................................................................... 303
(b) Non-Cemented Material ................................................................................................................ 303
(c) Cemented Material ........................................................................................................................ 303
5304 Plant and Equipment ................................................................................................................ 303
(a) General .......................................................................................................................................... 303
(b) Milling Equipment ........................................................................................................................ 303
5305 Construction.............................................................................................................................. 304
(a) General .......................................................................................................................................... 304
(b) Milling .......................................................................................................................................... 305
(i) General ..................................................................................................................................................... 305
(ii) Preparing the Pavement Surface ............................................................................................................... 305
(iii) Trial Milling.............................................................................................................................................. 305

(iv) Asphalt ...................................................................................................................................................... 305
(v) Cemented Material .................................................................................................................................... 305
5306 Storing Recovered Pavement Material ..................................................................................... 306
(a) General ..........................................................................................................................................306
(i) Material to be Reprocessed ....................................................................................................................... 306
(ii) Removal of Bituminous Layers (except Milled Material) ........................................................................ 307
(iii) Material from Existing Pavements which is not Reprocessed .................................................................. 307
(iv) Milling ...................................................................................................................................................... 307
(v) Measurement for Excavating Existing Pavement Material and Underlying Fill ....................................... 307
DIVISION 5400: GRAVEL WEARING COURSE AND GRAVEL SHOULDERS ................................................... 310
5401 Scope ........................................................................................................................................ 310
5402 Sources of Material ................................................................................................................... 310
5403 Material Requirements for Gravel Wearing Course .................................................................. 310
5404 Construction Requirements for Gravel Wearing Course .......................................................... 311
(a) Equipment ..................................................................................................................................... 311
(b) Oversize Material and Blending .................................................................................................... 311
(c) Transport, Placing and Spreading .................................................................................................. 311
(d) Compaction ................................................................................................................................... 311
(e) Trial Areas .....................................................................................................................................312
5405 Construction Requirements for Gravel Shoulders .................................................................... 312
(i) Level and Grade ........................................................................................................................................ 312
(ii) Width......................................................................................................................................................... 313
(iii) Thickness .................................................................................................................................................. 313
(iv) Cross Section ............................................................................................................................................ 313
5407 Testing ....................................................................................................................................... 313
(i) Routine Inspection and Testing ................................................................................................................. 313
DIVISION 5500: HAND-PACKED STONE PAVING AND MORTARED HAND-PACKED STONE PAVING .............. 317
5501 Scope ........................................................................................................................................ 317
5502 Materials.................................................................................................................................... 317
(a) Stones, Stone Chips and Kerb Stones............................................................................................ 317

(b) Blinding ........................................................................................................................................ 317
(c) Bedding Material .......................................................................................................................... 317
(d) Cement-Mortar .............................................................................................................................. 318
5503 Construction Equipment ........................................................................................................... 318
5505 Laboratory & Site Testing ......................................................................................................... 319
(a) General .......................................................................................................................................... 319
(b) Laboratory Testing ........................................................................................................................ 319
(c) Site Testing .................................................................................................................................... 319
DIVISION 5600 STONE SETTS AND COBBLESTONE PAVING .................................................................. 321
5601 Description ................................................................................................................................ 321
5602 Materials ................................................................................................................................... 321
(a) Stone Setts..................................................................................................................................... 321
(b) Dressed Stones and Cobblestones ................................................................................................. 321
(c) Blinding ........................................................................................................................................ 321
(d) Sand Bedding ................................................................................................................................ 321
(e) Cement Mortar .............................................................................................................................. 322
(a) Standard Procedure (Sand-Joints) ................................................................................................. 322
(b) Mortared Option............................................................................................................................ 323
5605 Laboratory & Site Testing ......................................................................................................... 323
(a) General .......................................................................................................................................... 323
(c) Site Testing .................................................................................................................................... 323
5606 Measurement and payment ...................................................................................................... 324

2
a) Stone Sett, Dressed stones and Cobblestones Paving square metre (m ) .................. 324
2
b) As in item 56.01 (a) – Mortared Option square metre (m ) .......................................... 324
DIVISION 5700 FIRED CLAY BRICK PAVEMENT ....................................................................................... 325
5701 Scope ........................................................................................................................................ 325
5702 Materials ................................................................................................................................... 325
(a) Fired Clay Bricks .......................................................................................................................... 325
(b) Joint in-fill..................................................................................................................................... 325

(c) Sand Bedding ................................................................................................................................ 325
(d) Cement Mortar .............................................................................................................................. 325
5703 Construction Equipment............................................................................................................ 326
5704 Construction .............................................................................................................................. 326
(a) Standard Procedure (Sand Joints) ..................................................................................................326
(b) Mortared Option ............................................................................................................................ 326
5705 Laboratory & Site Testing .......................................................................................................... 327
(a) General ..........................................................................................................................................327
(c) Site Testing ....................................................................................................................................327

2
a) Fired Clay Brick Paving square metre (m ).................................................................... 328
2
b) Fired Clay Brick Paving – Mortared Joints square metre (m )....................................... 328

LIST OF TABLES
Table 5104/1: Grading Requirements for Sub-base Material .............................................................. 277
Table 5104/2: Plasticity Limits for Natural Gravel Sub-bases ............................................................. 277
Table 5110/1: Testing Frequency ......................................................................................................... 281
Table 5204/1: Grading Limits for Graded Crushed Stone Road Base Materials (GB1) ...................... 286
Table 5204/2: Aggregate Strength and Durability Requirements for Crushed Stone Road Base
Materials (GB1) ........................................................................................................................... 286
Table 5205/1: Recommended Particle Size Distributions for Natural Gravels (Unstabilised and
Chemically Stabilised) for Road Base Material (GB2, GB3) ...................................................... 287
Table 5205/2: Durability Limits for Natural Gravels and Weathered Rocks for Use as Road Base
Material (GB2, GB3) ................................................................................................................... 289
Table 5205/3: Requirements for Chemically Stabilised Natural Gravels Road Base Material ............ 289
Table 5205/4: Particle size distribution for natural gravel base ........................................................... 291
Table 5205/5: Plasticity and grading requirements for natural gravel road base materials for low
volume roads .............................................................................................................................. 291
Table 5205/6: Plasticity and grading requirements for lateritic gravel road base materials ................ 292
Table 5211/1: Testing Frequency ......................................................................................................... 298
Table 5403/1: Material Specifications for Gravel Wearing Course ...................................................... 310
Table 5403/2: Material Specifications for Gravel Wearing Course for roads in ‘Urban or Settlement’
Areas............................................................................................................................................ 311
Table 5406/1: Longitudinal Grade Tolerance ....................................................................................... 312
Table 5407/1: Testing Frequency ........................................................................................................ 313
Table 5407/2: Density requirements: ................................................................................................... 313
Table 5502/1: Bedding Material Gradation .......................................................................................... 317
Table 5505/1: Laboratory Tests ........................................................................................................... 319
Table 5505/2: Site Inspection Criteria ................................................................................................. 319
Table 5605/1: Laboratory Testing ........................................................................................................ 323
Table 5605/1: Laboratory Testing ........................................................................................................ 327

Division 5100: Sub-Bases
5101 Scope
This Division covers the specification of materials for, and the construction of, sub-base pavement
layers including the in-situ recycling of existing pavements.
5102 Materials
Sub-base material shall be obtained from sources located by the Contractor and approved by the
Engineer or from existing pavement layers. The Contractor is required to obtain suitable sources,
which are closest to the area where sub-base is being placed.
5103 Material Sources for Sub-Bases

The materials used for the construction of sub-base layers shall be either:
 Natural Gravel;
 Scoria (Cinder Gravel);
 Weathered Rock;
 Crushed Gravel;
 Crushed Rock or crushed Boulders;
 Recycled Pavement Material.
 Any other granular material complying with the requirements of this Clause and a combination
of any of the above.
5104 Material Requirements Sub-Base
(a) General
Gravel material to be used for sub-base shall be obtained from approved sources in borrow areas,
cuttings or existing pavement layers and shall conform to requirements specified herein.
The aggregate used for crushed stone sub-base shall be derived from a parent rock that is hard,
sound, durable, and un-weathered and obtained from an approved quarry or clean sound boulders. It
shall contain no deleterious material such as decomposed rock, clay, shale, or mica. Single stage
crushing will not be allowed and the crusher installation shall be capable of producing material
complying with the specified requirements.
If the nature of the parent rock is such that despite every effort made, the material remains deficient in
the finer fractions, the Engineer may allow the addition of approved soil fines, crusher fines or sand in
controlled quantities not exceeding 15% by mass of the aggregate. Fines shall be introduced at the
crushing plant.
(b) Particle Size Distribution and Shape

The sub-base material shall comply with one of the gradings shown in Table 5104/1. It shall be well-
graded with a smooth continuous grading within the limits shown. Grading A is a broad grading to
accommodate natural gravels. Grading B and C are tighter gradings for specific nominal size
aggregate to reflect the greater control that is possible with crushed stone.

The minimum thickness of a constructed layer shall be greater than 1.5 times the maximum particle
size of the material.
Tests to determine whether the material complies with the specified grading requirements shall be
conducted after the material has been mixed and spread on the road.
Table 5104/1: Grading Requirements for Sub-base Material
Percentage Passing by Mass

ISO Sieve Natural Gravel Crushed Stone
Size (mm) B C
A
(37.5 mm) (28 mm)
63.0 100
50.0 100
37.5 70 – 100 95 – 100 100
26.5
20 50 - 100 60 – 80 70 – 85
9.5 40 – 60 50 – 65
4.75 30 - 100 25 - 40 35 – 55
2.36 15 - 30 25 – 40
1.0 17 - 75
0.425 11 - 56 7 - 19 12 – 24
0.075 5 - 25 5 - 12 5 - 12
The minimum Grading Modulus shall be 1.5, except where a material, having a lower Grading
Modulus (but not less than 1.2) is approved for use by the Engineer.
The flakiness index, determined by testing in accordance with BS812, Part 105 or ASTM D 3398, shall
not exceed 35.
(c) Plasticity
Natural gravel sub-base materials shall have a maximum Plasticity Index, when determined in
accordance with AASHTO T-90, depending on the climate as shown in Table 5104/2, or as shown on
the Drawings.
Crushed stone sub-base shall a Plasticity Index of less than 6 when determined in accordance with
AASHTO T-90.
Table 5104/2: Plasticity Limits for Natural Gravel Sub-bases
Typical Annual Plasticity Linear

Climate Liquid Limit
Rainfall (mm) Index Shrinkage
Moist tropical and wet tropical > 1000 < 35 <6 <3
Seasonally wet tropical > 500 and < 1000 < 45 < 12 <6
Arid and semi-arid < 500 < 55 < 20 < 10
(d) Density and Strength

The minimum dry density to which the material shall be compacted shall be 95% of the MDD obtained
in the AASHTO T-180 method D unless specified otherwise, shown on the Drawings or ordered by the
Engineer. Field dry densities shall be determined by the sand replacement method as specified in
AASHTO T 191 or any other method approved by the Engineer and calibrated with the sand
replacement method.
The minimum soaked Californian Bearing Ratio (CBR) shall be 30% when determined in accordance
with the requirements of AASHTO T-193. The Californian Bearing Ratio (CBR) shall be determined at
a density of 95% of the maximum dry density when determined in accordance with the requirements of
AASHTO T-180 method D.
(e) Use of Laterite as Sub-base

Laterite meeting the grading requirements can be used for sub-base for traffic levels up to 3 million
ESA provided the following criteria are satisfied:
 CBR (%) (after soaking) > 30
 Plasticity Index (%) < 25
The Plasticity Modulus (PM = PI x percentage passing the 0.425 mm sieve) shall not be greater than
500.
(f) Sub-base Materials for Low Volume Roads

A wider range of materials are suitable for sub-bases for low volume roads and for selected subgrade
or capping layers. The relevant tables of the prevailing version of the ERA Low Volume Roads Design
manual summarises the abbreviated nominal specifications used in the paved and unpaved catalogue
of designs. The quality of material to be used shall be described in the Particular Specifications.
5105 Construction Requirements
(a) General
Sub-base material shall be spread on the approved sub-grade by mechanical means without
segregation. The material shall be loosely spread in layers to give a compacted thickness not
exceeding 200 mm and not less than 100mm. The final compacted layer shall be free from
concentrations of coarse or fine materials.
The surface of each completed layer shall be moistened prior to the construction of the succeeding
layer. The optimum moisture content shall be determined according to AASHTO T 180 method D. The
aggregate shall be mixed and the moisture content adjusted to obtain a uniform mixture with moisture
content within 2 per cent of the optimum moisture content. The mixture shall be spread and shaped on
the prepared surface in a uniform layer.
The material shall be compacted by the use of approved rollers progressing gradually from the outside
towards the centre of the layer, except on super-elevated curves, where the rolling shall begin at the
low side and progress to the high side. Each layer shall be compacted full width. Each succeeding
pass shall overlap the previous pass by at least one third of the roller width. Rolling shall continue until
the entire thickness of each layer is thoroughly and uniformly compacted to a minimum 95 or 97 per
cent of the modified AASHTO maximum density as required on the Drawings; or as instructed by the
Engineer. The in-place density and moisture content shall be determined by the sand replacement
method as specified in AASHTO T 191 or any other method approved by the Engineer and calibrated
with the sand replacement method.
Along kerbs, headers, walls, and all places not accessible to the roller, the material shall be
compacted with approved tampers or compactors.
(b) Stabilisation
When specified in the Contract or required by the Engineer, sub-base layers shall be stabilised as
specified in Division 4500.

The entire thickness of the chemically stabilised layer shall be thoroughly and uniformly compacted to
a minimum 95 per cent of the modified AASHTO maximum density; or as required on the Drawings; or
as instructed by the Engineer.
(c) Trial Areas

than 1000 square metres using the materials and equipment proposed for the work to demonstrate
compliance with the requirements of this Clause.
(d) Traffic on Sub-base

The completed sub-base layer may be used by construction and public traffic subject to the approval
of the Engineer.
(e) Existing Pavement Layers

Where the thickness of any existing pavement layer requires to be supplemented and the thickness of
the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a
depth that will give a layer thickness of at least 100 mm after compacting together the loosened
existing and added material. In the case of gravel or crushed-stone sub-bases the Engineer may direct
the existing layer to be broken down to its full depth.
The composite layer shall be watered mixed and compacted as indicated in the sub-clause (a) of this
Clause.
5106 Construction Requirements for Sub-Bases Using Recycled (In-Situ)

Pavement Material
(a) General
Construction of sub-bases using recycled (in-situ) existing pavement materials shall comply with the
material requirements of Clause 5104 and with the construction requirements of this Clause.
(b) Milling/Scarifying
(i) Prior to scarification or milling, the surface of the existing pavement shall be clean and free
from soil and other deleterious matter.
(ii) The existing pavement shall be broken up to the depth shown in the Drawings either by
scarifying or by the use of an approved milling machine.
(c) Placing, Spreading and Compacting

Any material which is required to be added, to either supplement or modify the scarified milled
material, shall be evenly spread and thoroughly mixed into the scarified/milled material to form a
homogeneous material prior to compaction.
The material shall be placed, spread, watered and compacted in accordance with the requirements of
Clause 5105.
5107 Protection and Maintenance

The Contractor shall protect and maintain the completed sub-base. Maintenance shall include
immediate repairs of any damage or defects, which may occur and shall be repeated as often as is
necessary, or as instructed by the Engineer, to keep the sub-base continuously intact. Repairs shall be
made in a manner that will ensure restoration to an even and uniform surface.

5108 Sub-Base as a Filter or Separating Layer

This may be required to protect a drainage layer from blockage by a finer material, or to prevent
migration of fines and the mixing of two layers. The two functions are similar except that for use as a
filter, the material needs to be capable of allowing drainage to take place and therefore the amount of
material passing the 0.075 mm sieve must be restricted.
The following criteria should be used to evaluate a sub-base as a separating or filter layer:
𝐷15 (𝑐𝑜𝑎𝑟𝑠𝑒 𝑙𝑎𝑦𝑒𝑟)
a) The ratio should be less than 5
𝐷85 (𝑓𝑖𝑛𝑒 𝑙𝑎𝑦𝑒𝑟)
where D15 is the sieve size through which 15% by weight of the material passes and D 85 is the sieve
size through which 85% passes.
b) The ratio should be less than 25
For a filter to possess the required drainage characteristics a further requirement is:
c) The ratio should lie between 5 and 40
These criteria shall be applied to the materials at both the road base/sub-base and the sub-
base/subgrade interfaces.
(a) Levels
The lot (as defined and determined in sub-clauses 10203(a) and 10203 (b) respectively) shall be
deemed to comply with the requirements specified for surface levels if, before any repair work is
undertaken, at least 90% of the level measurements are within ± 25 mm of the specified levels.
Isolated spots, where the surface levels deviate by more than 33 mm of the specified levels shall be
repaired to bring the deviation to within the ± 25 mm tolerance.
(b) Width
The average width of the sub-base shall not be less than the specified width and nowhere shall the
outer edge of the sub-base be more than 75 mm inside the lines shown on the Drawings.
(c) Thickness
The lot (as defined and determined in sub-clauses 10203(a) and 10203 (b) respectively) will be
considered to comply with the requirements for layer thicknesses if:
 At least 90% of all the thickness measurements taken before any thickness repairs are made
is equal to or greater than the specified thickness minus 27 mm; and
 The mean layer thickness of the lot is not less than the specified thickness minus 5 mm.
Isolated spots where the actual thickness is less than the specified thickness less 35 mm shall be
repaired so as to fall within the 27 mm tolerance.
(d) Cross Section

At any transverse section the difference in level between any two points shall not vary by more than
20 mm from their difference in level as computed from the cross sections shown on the Drawings.

5110 Testing
(a) Process Control

The minimum testing frequency (in addition to source approval, that will be required from the
Contractor in terms of Clause 1202) for the purpose of process control, shall be as shown in
Table 5110/1.
Table 5110/1: Testing Frequency

Frequency
Test Minimum number of tests/lot
(one test every)
Materials
Field Density and Moisture Content 200 m 4
Atterberg limits and gradings 1 km 4
MDD & OMC 1 km
CBR 2 km
Other requirements as in Clause 5104 As directed by the Engineer
Construction Tolerances
Surface levels 20 m 3 points/cross section
Thickness 20 m 3 points/cross section
Width 20 m
Cross section 20 m

Routine inspection and testing will be carried out by the Engineer to test the quality of materials and
The density requirements specified in Clause 5104 for compaction of sub-base shall be deemed to
have been complied with if the minimum mean dry density for each lot exceeds 95% or 97% of
AASHTO T 180 MDD as specified; and no single measurement is less than 93%. In calculating the
mean, density values differing by more than 5 percentage points from the mean shall be disregarded
and a new mean calculated.
The determination of field dry density expressed as a percentage of AASHTO T 180 MDD implies an
AASHTO T 180 density determination for each field density. Where material is homogeneous, this ratio
can be decreased to one laboratory determination for up to four field densities
Any material or workmanship that does not comply with the specified requirements shall be removed
and replaced with materials and workmanship complying with the specified requirements, or if the
Engineer permits, be repaired as specified in Clause 1208(c) so that after being repaired it will comply
with the specified requirements.

Items 51.07 is applicable solely to work that has to be executed in a restricted area of which the width
is less than 3.0 m or the length is less than 150.0 m.
Item 51.01 Sub-base layer constructed from gravel or crushed stone

(a) Crushed stone (specify compacted layer thickness) compacted to:
(i) 95% of modified AASHTO density (specify compacted layer thickness) .................
3
........................................................................................................cubic metre (m )
(ii) 97% of modified AASHTO density (specify compacted layer thickness) ................
3
........................................................................................................cubic metre (m )

(b) Gravel sub-base (unstabilised gravel) compacted to:
(i) 95% of modified AASHTO density (specify compacted layer thickness) ..................
3
....................................................................................................... cubic metre (m )
(ii) 97% of modified AASHTO density (specify compacted layer thickness) .................
3
....................................................................................................... cubic metre (m )
The unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall
be calculated from the authorized dimensions of the completed layer.
The tendered rates shall include full compensation for procuring; processing; production operations;
haulage and transport; placing and compacting the material; protection and maintenance of the layer;
and the conducting of control tests; all as specified.
Item 51.02 Sub-base layer constructed from non-cemented or cemented gravel; or crushed
stone obtained from existing pavement layers
(a) Crushed Stone sub-base (unstabilised) compacted to 95% or 97% of modified AASHTO
density as required on the Drawings using:
3
(i) Non-cemented material (specify compacted layer thickness) ....... cubic metre (m )
3
(ii) Cemented material (specify compacted layer thickness) .............. cubic metre (m )
(b) Gravel sub-base compacted to 95% or 97% of modified AASHTO density as required on the
Drawings, using:
3
3
The unit of measurement shall be the cubic metre of compacted pavement layer, the quantity of which
shall be calculated in accordance with the authorized dimensions of the completed layer if the
underlying layer has also been reconstructed or reworked. Where the underlying layer has not been
reconstructed or reworked but only rolled, or where no work has been done on it, quantities shall be
calculated with the aid of cross-sections taken of the layer before and after construction. Where the
material consists of recovered pavement material in part and imported material in part the quantity of
imported material obtained from cut or borrow shall be paid for under pay item 51.01, calculated in
accordance with the volume relation of the respective materials.
The tendered rate shall include full compensation for breaking up the existing pavement layer;
excavating the material in the existing pavement; procuring; breaking down; watering and compacting
the floor of the excavation; haulage and transport; placing and compacting the material; protection and
maintenance of the layer; and for the performance of control tests; all as specified.
Where excavation is executed over sections of the road, payment shall also include compensation for
the proper measuring and marking-off of the excavation, and the protection of the adjacent existing
pavement and its repair should it be damaged.
The tendered rate for re-using existing cemented material shall include full compensation of breaking
down the material to comply with the specified grading requirements.
Item 51.03 In-situ reconstruction of existing Sub-base layer as:

(a) Crushed stone Sub-base (unstabilised) compacted to 95% of modified AASHTO density,
using:
3
3
(ii) Cemented material (specify compacted layer thickness) ............ cubic metre (m )
(b) Gravel sub-base (unstabilised gravel) compacted to 95% or 97% of modified AASHTO density
as required on the Drawings, using:
3
3
The unit of measurement shall be the cubic metre of compacted pavement layer reworked in-situ, the
quantity of which shall be calculated in accordance with the authorized dimensions of the completed
layer.
The tendered rate shall include full compensation for breaking up the existing pavement layer to the
specified depth; breaking down and preparing the material; watering and compacting the floor of the
excavation; placing and compacting the material as well as the protection and maintenance of the
layer, conducting control tests, measuring and demarcating the work where layers are reprocessed
partly, protecting the adjacent pavement and its repair should it be damaged.
The tendered rate shall also include full compensation for spreading and mixing in any additional
material should the existing layer thickness be inadequate and where it is specified, or instructed by
the Engineer, that the thickness be increased.
Material which is temporarily bladed to windrow for the removal of an underlying layer and then bladed
back and compacted, will be classed as in-situ reconstruction and paid for under this item. The
temporary blading of the material to windrow will be paid for under Pay item 51.05.
The tendered rate for cemented material shall include full compensation for breaking down the
material to comply with the specified grading requirements.
Item 51.04 Extra over Pay item 51.02 for adding extra material
3
(a) Gravel sub-base ..........................................................................................cubic metre (m )
(b) Crushed stone Sub-base .............................................................................cubic metre (m³)
The unit of measurement shall be a cubic metre of material added on the instruction of the Engineer.
The quantity shall be determined by way of cross-section measurement.
The tendered rate shall include full compensation for procuring; haulage and transport; and adding the
material to the in-situ broken down pavement layer.
Item 51.05 Extra over Pay item 51.03 for temporarily blading the material to windrow
3
The unit of measurement shall be a cubic metre (m ) of material from an existing pavement layer,
temporarily bladed to windrow and measured in its original position before removal.
The tendered rate shall include full compensation for all additional costs involved in temporarily
blading the material to windrow; blading back; and also for all clearing-up work which may be
necessary after the material has been bladed back.
Only material bladed to windrow on the instruction of the Engineer in order to expose the underlying
layer, shall be measured and paid for.
Material bladed or cut from restricted areas to windrow, and material temporarily stockpiled, will not be
paid for under this item.
Item 51.06 Extra over Pay item 51.02 for excavating material in existing pavement layers in
restricted areas
3
(a) Non-cemented material ...............................................................................cubic metre (m )

3
(b) Cemented material...................................................................................... cubic metre (m )
The unit of measurement shall be a cubic metre of material excavated in a restricted area, the quantity
of which shall be calculated in accordance with the area and the average thickness of the layers
excavated.
The tendered rate shall include full compensation for all additional costs for excavating and
compacting the floor of the excavation in a restricted area, irrespective of the compaction plant used
and the material in restricted areas.

Division 5200: Road Bases (excluding bituminous bases)
5201 Scope
This Division covers the specifications of materials for, and the construction of road base pavement
layers. It includes the use of crushed, screened or crushed and screened stones or gravels, natural
gravels, and stabilised base materials.
Bituminous base materials are covered in Series 6000.
5202 Dimensions
The road base layer shall be constructed to the dimensions and cross sectional profiles shown on the
Drawings.
5203 Materials
(a) Sources of Material

Road base material shall be obtained from sources located by the Contractor and approved by the
Engineer.
(b) Road Base Material Types

The materials used for the construction of road base layers shall be one of the following as described
in the Contract:
 Crushed rock or stone;

 Naturally occurring granular materials and weathered rock, either unstabilised or chemically
stabilised as specified in Division 4500;
5204 Material Requirements for Crushed Stone
(a) General
Graded crushed stone (GB1) (as defined in the prevailing ERA Flexible Pavement Design Manual)
shall be produced by crushing fresh, quarried rock and may be an all-in product, usually termed a
'crusher-run', or alternatively the material may be separated by screening and recombining to produce
a desired particle size distribution, as per the specifications. The material shall be clean and free from
organic matter, lumps of clay or other deleterious substances. The material shall be of such a nature
that it can be readily transported, spread and compacted without segregation.

The combined grading of the material shall be a smooth continuous curve falling within the grading
limits shown in Table 5204/1 when determined in accordance with the requirements of AASHTO T-27.
The mass of material passing the 0.075 mm sieve shall be determined in accordance with the
requirements of AASHTO T-11.
The flakiness index determined in accordance with BS 812, Part 105 or ASTM D 3398 shall not
exceed 30 per cent.

Table 5204/1: Grading Limits for Graded Crushed Stone Road Base Materials (GB1)
Percentage by mass of total Aggregate passing test sieve
Test sieve
Nominal maximum particle size
(mm)
37.5 mm 28 mm 20 mm
50 100 - -
37.5 95 – 100 100 -
28 - - 100
20 60 – 80 70 - 85 90 – 100
10 40 – 60 50 - 65 60 – 75
5 25 - 40 35 - 55 40 – 60
2.36 15 – 30 25 - 40 30 – 45
0.425 7 – 19 12 - 24 13 – 27
(1)
0.075 5 – 12 5 - 12 5 – 12
1
For paver-laid materials a lower fine content may be accepted.
(c) Plasticity Index

The fine fraction of a GB1 material shall be non-plastic when determined in accordance with
AASHTO T-90.
(d) Density, Strength and Durability

The in-situ dry density of the placed material should be a minimum of 98% of the maximum dry density
obtained from AASHTO T-180 method D (hereinafter also referred to as modified AASHTO density); or
as indicated on the Drawings; or as indicated in the Particular Specifications; or on instruction of the
Engineer. The compacted thickness of each layer should not exceed 200 mm.
Crushed stone road base constructed with proper care with GB1 materials should have CBR values in
excess of 100 per cent.
The strength and durability requirements of crushed stone shall be assessed using the 10% Fines
Aggregate Crushing Test (10% FACT) (SANS 3001-AG10) in terms of the dry and wet strength, and
the wet/dry ratio related to rock type as specified in Table 5204/2.
Table 5204/2: Aggregate Strength and Durability Requirements for Crushed Stone Road Base
Materials (GB1)
10% FACT
Rock Type Matrix Dry Wet Wet/Dry ratio
(min kN) (min kN) (min)
General requirement for most rock types 110 75
Non-siliceous cementing
140 75
material
Arenaceous
Siliceous cementing
110 75
material
Diamictites (Tillites) 200 70
Argillaceous 180 125
Other simpler tests such as the Aggregate Impact Test (British Standard 812, Part 112, 1990) may be
used in quality control testing provided a relationship between the results of the chosen test and the
10% FACT has been determined.

(e) Soluble Salts (< 6.7 mm fraction)

-1
Where the electrical conductivity (EC) tested to SANS 3001 AG32 is 0.15 Sm and below, the material
may be used.
-1
For material with EC > 0.15 Sm , the pH shall be determined.
For material with pH < 6, the material shall be treated with lime until the pH = 10. The material may
then be used. (Note: The aggregate is normally treated at the crusher and if the pH exceeds 10 at the stage, the decrease at
any later stage shall be ignored should the pH remain ≥ 8)
For material with pH ≥ 6 the material shall be used as it is.
5205 Material Requirements for Natural Gravels
(a) General
Graded Natural Gravel (GB2 and GB3) as defined in the prevailing ERA Flexible Pavement Design
Manual are covered.
A wide range of materials including lateritic, calcareous and quartzitic gravels; river gravels; boulders
and other transported gravels; or granular materials resulting from the weathering of rocks can be
used successfully as road base materials. The material shall be of such a nature that it can be readily
excavated, transported, spread and compacted without segregation.

The particle size distribution should be approximately parallel with the grading envelope, to ensure that
the material has maximum mechanical stability, in the grading limits shown in Table 5205/1 when
determined in accordance with the requirements of AASHTO T-27. The mass of material passing the
0.075 mm sieve shall be determined in accordance with the requirements of AASHTO T-11.
Table 5205/1 contains three recommended particle size distributions for suitable materials
corresponding to maximum nominal sizes of 37.5 mm, 20 mm for unstabilised base material and 37.5
mm nominal size for chemically stabilised material.
Table 5205/1: Recommended Particle Size Distributions for Natural Gravels (Unstabilised and
Chemically Stabilised) for Road Base Material (GB2, GB3)
ISO Test sieve Percentage by mass passing
(mm) Natural Gravel Chemically stabilised
37.5 mm 20 mm 37.5 mm
50 100 - 100
37.5 80 – 100 100 80 - 100
19 60 – 80 80 – 100 60 - 100
9.5 45 – 65 55 – 80 -
4.75 30 – 50 40 – 60 30 – 80
2.00 20 – 40 30 – 50 20 – 63
0.425 10 – 25 12 – 27 10 – 41
0.075 5 – 15 5 – 15 5 - 20
To meet the requirements consistently, screening and crushing of the larger sizes may be required.
The fraction coarser than 10 mm should consist of more than 40 per cent of particles with angular,
irregular or crushed faces. The mixing of materials from different sources may be warranted in order to
achieve the required grading and surface finish. This may involve adding fine or coarse materials or
combinations of the two.
The flakiness index shall not exceed 30% when determined in accordance with BS 812 Part 105-1990.

(c) Plasticity Index

The fine fraction of GB2 and GB3 material shall have a maximum Plasticity Index of 6 when
determined in accordance with AASHTO T-90.
If the PI approaches the upper limit of 6, it is desirable that the fines content (passing 0.425 mm sieve)
be restricted to the lower end of the range. To ensure this, a maximum Plasticity Modulus (PM) of 90 is
required where:
PM = PI x (percentage passing the 0.425 mm sieve)
In drier climatic areas
The addition of low percentages of hydrated lime or cement to reduce the PI to acceptable limits
without satisfying the Initial Consumption of Stabiliser (SANS 30001 GR-57) of the material and
creating a stable chemically stabilised material shall not be allowed unless approved by the Engineer.
The minimum Grading Modulus for material once placed and compacted on the road shall be:
 For natural material 2.00

 For material to be chemically stabilised 1.75
(d) Density, Strength and Durability

When used as a road base, the material should be compacted to a density equal to or greater than
that specified in 5208(b) of the maximum dry density achieved using the AASHTO T-180 D method.
When compacted in the laboratory to 98% of Modified AASHTO density, the material should have a
minimum CBR of 80% after four days immersion in water (ASTM D 1883).
The durability of certain natural gravel base materials are known to be susceptible to disintegration in
service and production of plastic fines which could be detrimental to the performance of the road. The
material dependent specifications for the durability of natural gravel base material are shown in
Table 5205/2 and are based on the Durability Mill Index (DMI) to method (SANS 3001 AG16), the
modified Aggregate Impact Value (AIV, based on BS 812, Part 112, 1990) and the 4-day ethylene
glycol soaked modified AIV compared with soaked modified AIV.
The modified AIV is the number of blows that yields 5 – 20 % fines passing the 2.36 mm sieve and is
calculated as:
Mod AIV = %P2.36 x 15/n (where n = Number of Blows)
The test should be done on dry aggregate, water soaked aggregate and aggregate soaked for 4 days
in ethylene glycol.
Requirements expressed in terms of the results of the Aggregate Crushing Value (ACV) (British
Standard 812, Part 110) may be used to supplement the requirements in Table 5205/2. The ACV shall
be less than 25 which equates directly to the normal AIV value from BS 812, Part 112, 1990.
The Los Angeles Abrasion value, determined by testing in accordance with AASHTO T96 shall not
exceed 45 at 500 revolutions unless otherwise specified in the Particular Specifications.

Table 5205/2: Durability Limits for Natural Gravels and Weathered Rocks for Use as Road Base
Material (GB2, GB3)
Durability Mill Test Aggregate Impact Value Test

% Passing
Typical 4-day
Rock Type 0.425 mm Modified Modified AIV
examples DMI Glycol
after AIV (dry) wet/dry ratio
soaked
treatment
Basalt < 2%
Basic Dolerite increase
< 125 < 35 < 39 < 114%
Crystalline Gabbro from wet
AIV
Acid Granite
< 420 < 35 < 39 < 114% N/A
Crystalline Gneiss
Quartzite
High Silica
Chert N/A N/A <39 < 114% N/A
rocks
Hornfels
Sandstone
Arenaceous Arkose
< 125 < 35 < 31 < 114% N/A
rocks Conglomerate
Siltstone
Shale
Argillaceous Wet AIV
Mudrocks < 125 < 35 < 24 N/A
rocks < 26
Phyllite
Dolomite
Carbonate
Limestone N/A N/A < 39 < 114% N/A
rocks
Marble
Tillites
Diamictites < 125 < 35 < 22 < 115% N/A
Greywacke
Calcrete
Pedogenic < 114%
Ferricrete < 480 < 40 < 39 N/A
material (calcretes < 120%)
Silcrete
(e) Chemically Stabilised Natural Gravel Base

Chemically stabilised natural gravel materials using stabilisers as specified in sub-clause 4502(b)(i),
(ii), (iii) and (iv) and meeting the grading requirements of Table 5205/1 shall have the requirements
shown in Table 5205/3 unless specified on the Drawings or instructed by the Engineer:
Table 5205/3: Requirements for Chemically Stabilised Natural Gravels Road Base Material
Grading to be within the limits shown in Table

Material before treatment
5205/1
PI after treatment Slightly plastic or non-plastic
100% Mod Minimum 1.5
Unconfined AASHTO density Maximum 3.0
Compressive Strength
(MPa) 97% Mod Minimum 1.0
AASHTO density Maximum 2.0
Indirect tensile Strength – 100% mod AASHTO density
250
(kPa)
(1) Initial Consumption of Stabiliser (ICS) (SANS
Stabiliser content
3001 GR-57) + 1%
Wet/Dry durability using the mechanical brush test to
< 8% loss
SANS 3001 GR 56
N/A
Carbonated UCS strength If the ICS requirement is satisfied, carbonation of
stabilised layers is unlikely
(1)
Stabiliser contents of >3% may not be economically viable

(f) Soluble Salts
(i) Untreated material

The requirements of sub-clause 5204 (e) shall apply.
(ii) Material to be stabilised with lime or cement

-1
Where the pH ≥ 6, the EC < 0.02 Sm and a qualitative test using Barium Chloride to identify the
presence of sulphates is negative, the material may be used.
If pH and/or EC requirements are not; or a white precipitate of Barium Sulphate is observed when
Barium Chloride is added to a solution of the < 6.7mm of the material; the material shall be further
investigated as instructed by the Engineer.
(g) Natural Gravels Base for Low Volume Roads

A wider range of materials are suitable for the base for low volume roads and are dependent on traffic
categories and climate. The prevailing version of the ERA Low Volume Roads Design manual
summarises the abbreviated nominal specifications used in the paved and unpaved catalogue of
designs. The quality of material to be used will be described in the Particular Specifications or as
approved by the Engineer and shall be controlled by the design CBR at a minimum of 98% modified
AASHTO density.
The grading envelopes for road base for low volume roads are shown in Table 5205/4. Envelope A
varies depending whether the nominal maximum particle size is 37.5mm, 20mm or 10mm. A
requirement of five to ten per cent retained on successive sieves is required at design traffic levels
>0.3 mesa to prevent excessive loss in stability. Envelope C extends the upper limit of envelope B to
allow the use of sandy materials, but its use is not permitted in wet climates.
Envelope D is similar to a gravel wearing course specification, and shall be used for very low traffic
volumes as indicated in Table 5205/5. The grading is specified only in terms of the grading modulus
(GM) and can be used in both wet and dry climates.
The plasticity requirements are shown in Table 5205/5. For dry environments, the plasticity index and
plasticity modulus for each traffic and subgrade class can be increased by 20 and 40 per cent
respectively, depending on the crown height and whether unsealed or sealed shoulders are to be used
on instruction of the Engineer.

Table 5205/4: Particle size distribution for natural gravel base
Per cent by mass of total aggregate passing test sieve

ISO Test
Envelope A
Sieve
Nominal maximum particle size Envelope B Envelope C
size
37.5mm 20mm 10mm
50mm 100 100
37.5mm 80-100 100 80-100
19mm 55-95 80-100 100 55-100
9.5mm 40-80 55-85 60-100 40-100
4.75mm 30-65 30-65 45-80 30-80
2.00mm 20-50 20-50 35-75 20-70 20-100
1.00mm - - - - -
425µm 8-30 12-30 12-45 8-45 8-80
300µm - - - - -
75µm 5-20 5-20 5-20 5-20 5-30
Envelope D
1.65 < GM < 2.65
Table 5205/5: Plasticity and grading requirements for natural gravel road base materials for low
volume roads
Traffic class (mesas)

Subgrade LV1 LV2 LV3 LV4 LV5 LV6
Property
class 0.01-
<0.01 0.05-0.1 0.1-0.3 0.3-0.5 0.5-1.0 1.0-3.0
0.05
Ip <12 <12 <9 <6 <6 <6 <6
S2 PM <400 <250 <150 <120 <90 <90 <90
Grading B B B A A A A
Ip <15 <12 <12 <9 <6 <6 <6
S3 PM <550 <320 <250 <180 <90 <90 <90
1
Grading C B B B A A A
Ip Note 2 <15 <12 <12 <9 <9 <6
S4 PM <800 <450 <320 <300 <200 <90 <90
3
Grading D B B B B A A
Ip Note 2 <15 <15 <12 <12 <9 <6
S5 PM - <550- <400- <350- <250- <150- <90-
3 1
Grading D C B B B A A
Ip Note 2 <18 <15 <15 <12 <9 <6
S6 PM - -<650 <550 <500 <300 <180 <90
3 1 1
Grading D C C B B A A
Notes:
(1) Grading ‘C’ is not permitted in wet environments or climates (N<4); grading ‘B’ is the minimum
requirement
(2) Maximum Ip = 8 x GM
(3) Grading ‘D’ is based on the grading modulus 1.65 < GM < 2.65
(4) All base materials are natural gravels; subgrades are non-expansive

(i) Lateritic road base gravels

The requirements for lateritic gravels for road bases are slightly different to those given for other natural
gravels. These are shown in Table 5205/6. The quality of material to be used will be described in the
Particular Specifications or as approved by the Engineer and shall be controlled by the design CBR at
a minimum of 98% modified AASHTO density.
For design traffic levels greater than 0.3 mesa, the liquid limit should be less than 30. Below this traffic
level the liquid limit shall be less than 35. Where sealed shoulders of at least one metre width are
pr102ovided, the maximum plasticity modulus may be increased by 40 per cent. A minimum field
3
compacted dry density of 2.0 Mg/m is required for these materials.
Table 5205/6: Plasticity and grading requirements for lateritic gravel road base materials
Traffic class (mesas)

Subgrade
Property LV1 LV2 LV3 LV4 LV5 LV6
class
<0.01 0.01-0.05 0.05-0.1 0.1-0.3 0.3-0.5 0.5-1.0
Ip <15 <15 12< <9 <9 <6
S2 PM <400 <250 <150 <150 <120 <90
Grading B B B A A A
Ip <18 <15 <15 <12 <9 <6
S3 PM <550 <320 <250 <180 <120 <90
1
Grading C B B B A A
1
Ip <20 <18 <15 <15 <9 <9
S4 PM <800 <450 <320 <300 <200 <90
Grading GM 1.6-2.6 B B B B A
1
Ip <25 <20 <18 <15 <12 <9
S5 PM - <550- <400- <350- <250- <150-
Grading GM 1.6-2.6 B B B B B
1
Ip <25 <20 <20 <18 <15 <12
S6 PM - -<650 <550 <400 <300 <180
Grading GM 1.6-2.6 B B B B A
Notes:
(1) Maximum Ip = 8 x GM
(2) Unsealed shoulders are assumed. Further modification to the limits can be made if the shoulders are sealed.
(3) The compaction requirement for the soaked CBR test is 100% Mod. AASHTO with a minimum soaking time of 4 days
or until zero swell is recorded. This is a relaxation of the soaked CBR requirement for natural gravel base materials
given in the LVR design catalogues.
(ii) Basic Igneous Rock (including Basaltic and Doleritic Gravels) for Road Base Gravels
The durability limits shown in Table 5205/2 shall apply for basic igneous rock for road base in sealed
low volume roads unless approved otherwise by the Engineer.
In dry climatic areas (N>4), the materials can be used unmodified up to a maximum plasticity index of
10. However, the materials should not be used in wet areas unless chemically stabilised.
(iii) Cinder gravels

Cinder gravels can be used as base for lightly trafficked paved roads in Ethiopia in accordance with
the requirements of the prevailing version of the ERA LVR design manual.
5206 Material Requirements for Dense Bitumen Macadam Base

The specifications are given in Division 6400.

5207 General Construction Requirements

Pavement layers shall be constructed only where the underlying layer meets all the specified
requirements and has been approved by the Engineer. Prior to construction of the base and before
any material for the base is dumped on the road, the Contractor shall check the underlying sub-base
layer to establish whether there is any damage, wet-spots or other damage which shall be rectified as
Where the in situ base material is to be reworked or reconstructed, the floor of the excavated material
(top of sub-base) shall first be watered and rolled as instructed by the Engineer.
5208 Construction Requirements for Crushed Stone Base
(a) Equipment
The material shall be laid by grader or a self-propelled paving machine, as described in the Contract
and shall be capable of producing a mixture of laid material complying with the requirements of this
Specification.
The equipment used shall be of adequate capacity, in good working order, and subject to the approval
of the Engineer.
Obsolete or worn out equipment will not be permitted on the Site.
For material laid by a paving machine, the mixing plant shall be either a batch or a continuous type, as
approved by the Engineer, and shall be equipped with satisfactory means of accurately controlling the
proportions of all constituent materials.
The crushing and screening plant shall be capable of crushing and screening the aggregates, to be
used for crushed stone base material, into at least four different sized fractions.
Compaction shall be carried out using self-propelled 8 – 10 tonnes deadweight smooth wheeled rollers
having a width of roll not less than 450mm; or by multi-wheeled pneumatic tyred rollers of equivalent
mass; or by vibratory rollers of equivalent compactive performance; or by a combination of these.
(b) Trial Section and Other Requirements Prior to Construction of the Crushed Stone Base
Before any crushed-stone layer is constructed, the following requirements shall be met:
 Approval of crushed stone base material shall be granted only after the successful
construction of a trial section or sections complying in all respects with the specifications,
including density and grading.
 No base material, except for the trial sections, shall be placed on the road unless the engineer
has approved the crushed stone base material in writing.
 A trial section shall be constructed from material from a proposed source (before 5 000 m³ has
been produced), to prove the quality and compactibility of the material and to agree to a target
grading for future construction lots where essentially the same material is used and it is
processed essentially in the same manner.
 The trial section shall be constructed on a layer of the specified sub-base standard and shall
be placed as instructed by the Engineer with due regard to the approved construction
programme.
 The trial section shall be between 150 m and 200 m in length, or as otherwise ordered by the
Engineer. The width shall be as ordered by the Engineer, whilst the thickness shall be the
same as the base thickness specified for the pavement structure.

 The trial section shall be adequately assessed by the Engineer prior to proceeding with the
next trial section where so ordered, in order to rectify identified shortcomings.
 If a trial section fails, it shall be removed as excess/unsuitable material, unless it is structurally
acceptable to the Engineer to be retained as sub-base.
 Where further trial sections are required for approval, the failed sections shall be removed
before further trial sections may be constructed. Only trial sections in which the base material
complies with all the requirements of the specifications shall be paid for. Payment for the
construction of base will be made under the relevant pay items of Clause 5212. No payment
will be made for trial sections removed as excess/unsuitable material.
 The crushing of aggregate for the base from any source, or the stockpiling of crushed stone in
stockpiles, shall be restricted to 5 000 m³ until the material has been approved by the
Engineer.
 Material shall be furnished only from sources approved by the Engineer, who may cancel his
approval should in his opinion, the particular source, have become unsuitable. Approval of the
crushed-stone material for the base will not relieve the contractor of his responsibility to
produce a finished crushed stone base constructed according to the specifications
 Shoulders shall be included in the trail sections and constructed in accordance with the
Drawings or as instructed by the Engineer
 No crushed-stone layer shall be rolled if the underlying layer, either on account of rain or by
any other cause, is so wet as to constitute a danger of the underlying layers being damaged.
(c) Placing and Compaction

The surface on which the crushed stone base is to be laid shall be free from loose or deleterious
material.
For materials laid by a paving machine:
 The aggregate shall be recombined in a mixing plant in the proportions necessary to produce
a smooth continuous combined grading curve complying with the requirements of Table
5204/1.
 The mixing plant shall be an approved type and shall be equipped with satisfactory means of
controlling the mix proportions and the addition of the required quantity of water to achieve the
optimum, which is required for compaction purposes.
 The mixed material shall be transported at the required moisture content and in such a way,
that no segregation occurs.
 The rate of travel of the paver and its method of operation shall be adjusted to produce an
even and uniform flow of material across the full laying width free from dragging and without
segregation.
Whether by grader or paving machine, the material shall be spread in layers not exceeding 200 mm
and not less than 100 mm compacted thickness.
towards the centre of the layer, except on superelevated curves, where the rolling shall begin at the
low side and progress to the high side. Each succeeding pass shall overlap the previous pass by at
least one third of the roller width. Rolling shall continue until the entire thickness of each layer is
thoroughly and uniformly compacted to the specified density.

Any area, which is inaccessible to rolling equipment, shall be compacted by means of mechanical
tampers or other equipment approved by the Engineer.
Upon completion of compaction, the surface of the completed layer shall be tightly bound, free from
movement under the compaction plant, and free from laminations, ridges, cracks or loose or
segregated material.
The in-situ density of the completed layer shall not be less than 98% of the maximum dry density
determined in accordance with the requirements of AASHTO T180 method D unless specified
otherwise on the Drawings or instructed by the Engineer.
The in-situ density of the completed layer shall be determined in accordance with the requirements of
AASHTO T-191 (sand replacement method) or any other method approved by the Engineer and
accurately calibrated with the AASHTO T-191 method.
(d) Watering and Slushing

Where specified or on instruction by the Engineer, after completion of the compaction process,
sections shall be watered and slushed either by the continuous or multi-stage process.
(i) Continuous Process

Immediately after completion of the compaction described in Sub-clause 5208(c), short sections of the
surface shall be thoroughly watered, rolled and slushed by means of steel-wheeled rollers with a mass
of not less than 12 tonnes each, and/or with pneumatic-tyred rollers. The process shall continue until
all excess fines are brought to the surface.
The grout thus formed shall be uniformly broomed over the surface with stiff brooms to correct any
areas still deficient in fines, whereupon the excess fines shall be broomed from the surface of the
layer. This process shall continue until all excess fines in the mixture have been brought to the surface
of the layer and its specified density has been reached. Excess fines and loose aggregate shall then
be swept from the surface while the surface is still damp, and the layer shall then be allowed to dry
out.
During slushing operations, care shall be taken not to roll the surface out of shape. The slushing
process shall be carried out on each section in one continuous process, and each section shall be
completed before the next is proceeded with.
After completion of the slushing and brooming process, when the layer is wind-dried, the surface shall
be finally rolled with a steel-wheeled roller. The completed layer shall be firm and stable with a closely-
knit surface of aggregate exposed in mosaic and free from nests of segregated material, laminations
or corrugations. The Engineer may permit omission of the slushing process in the lower layer of a two-
layer base, provided that the specified density is obtained in each of the layers.
(ii) Multi-stage Process (water or slurry rolling)

After the base has been compacted to the required density at optimum moisture content and has then
been allowed to dry out to less than 50% of the optimum moisture content, the final surface of the
base shall be watered and subjected to additional rolling (the so-called "slurry" or "water" rolling) in
order to obtain a firm, even, well-knit surface. Watering, rolling with suitable rollers, and sweeping with
stiff brooms shall continue until all excess fines on the surface have been distributed over the surface
of the base. Any areas deficient in fines shall be corrected by the addition of fine aggregate from the
same source of supply as the crushed aggregate, and by brooming such fine aggregate into the
surface voids of the layer until a firm base with a closely knit surface is obtained, free from nests of
segregated materials, loose aggregate or other irregularities.
All excess fines which cannot be redistributed shall be removed by brooming whilst still wet from the
slurry roll watering, and the base shall then be allowed to dry out once again to less than 50% of the

optimum moisture content so as to present an exposed mosaic of regular stone faces free from fine
aggregate and foreign matter before any further treatment of the surface may be carried out.
When using entirely non-plastic bases, it may be necessary to remove the final portions of excess
fines from the surface after the base has been allowed to dry out to a degree which will be determined
only by practical trial and error in each specific case of such a non-plastic base. The completed layer
shall be firm and stable with a closely knit surface aggregate exposed in mosaic and free from nests of
segregated material, laminations or corrugations. During surface preparation of the base, care shall be
taken not to roll the surface out of shape
(e) Stabilisation
When specified in the contract or required by the Engineer, base layers shall be stabilised as specified
in Division 4500.
(f) Traffic on Road base

The completed road base layer shall not be used by construction or public traffic prior to the
application of the prime coat in accordance with the requirements of Division 6100 of these
specifications and without the prior written approval of the Engineer.
The approval by the Engineer shall not relieve the Contractor of his obligations to maintain the road
base in a satisfactory condition and to undertake any repairs as instructed by the Engineer.
5209 Construction Requirements for Natural Gravel Road Base
(a) Equipment
The material for the construction of all roads using natural gravel bases shall be placed, spread,
broken down (where necessary), watered and mixed by means of a grid roller and grader. The
operations shall be so designed as to produce a mixture of laid material complying with the
requirements this Specification.
The equipment used shall be of adequate rated capacity in good working order and subject to the
approval of the Engineer.
Obsolete or worn out equipment will not be permitted on the Site.
Compaction shall be carried out using self-propelled 8 – 10 tonnes deadweight smooth wheeled rollers
having a width of roll not less than 450mm; or by multi-wheeled pneumatic tyred rollers of equivalent
mass; or by vibratory rollers of equivalent compactive performance; or a combination of these.
(b) Placing and Compaction

The sub-base surface on which the natural gravel road base is to be laid shall be free from loose and
deleterious material. The road base shall be spread on the sub-base material by mechanical means
without segregation.
The material shall be loosely spread in layers to give a compacted thickness not exceeding 200 mm
and not less than 100mm. The final compacted layer shall be free from concentrations of coarse or
fine materials.
The surface of each completed layer shall be moistened prior to the construction of the succeeding
layer.

Prior to compaction, the moisture content of the spread material shall be adjusted as necessary either
by the uniform application of water or drying out, to achieve within -1% to +2% of the optimum
moisture content when determined in accordance with AASHTO T-180.
towards the centre of the layer, except on super-elevated curves, where the rolling shall begin at the
The in-situ density of the completed layer shall not be less than 98% of the maximum dry density
determined in accordance with the requirements of AASHTO T-180 method D.
The in-situ density of the completed layer shall be determined in accordance with the requirements of
AASHTO T-191 or any other method approved by the Engineer and accurately calibrated with the
AASHTO T-191 method.
(c) Stabilisation
When specified in the contract or required by the Engineer, base layers shall be stabilised as specified
in Division 4500 and shall meet the material requirements of Table 5205/3.
(d) Trial Sections

Prior to the commencement of normal working the Contractor shall construct a trial section of not less
than 1 000 m² using the materials and equipment proposed for the work to demonstrate compliance
with the requirements of this Clause.
(e) Traffic on Road Base

The completed road base layer shall not be used by construction or public traffic prior to the
application of the prime coat in accordance with the requirements of Division 6100 of these
specifications and without the prior written approval of the Engineer.
Such approval shall not relieve the Contractor of his obligations to maintain the road base in a
satisfactory condition and to undertake any repairs as instructed by the Engineer.
5210 Construction Requirements for Dense Bitumen Macadam Road Base

Provisions described in Division 6400 shall apply.
(a) Process Control

The minimum testing frequency, in addition to source approval, that will be required from the
Contractor in terms of Clause 1202 for the purpose of process control shall be as shown in Table
5211/1.

Interval
Test after Processing and Compaction
(one test every)
Field Density and Moisture Content 75 m
Atterberg limits and gradings 150 m
Materials MDD & OMC 2 km
CBR & ACV 2 km
Other physical requirements as in As directed by the
Clauses 5204 and 5205 Engineer
Surface Levels As per Clause
Construction Base layer thickness 10205 (a)
Tolerances Base layer width 20 m
Cross Section 20 m
(b) Surface level

The surface level shall be checked for compliance in accordance with Clause 10205. The lot shall be
deemed to comply with the requirements specified for surface levels if, before any repair work is
undertaken, at least 90% of the level measurements are within ± 20 mm of the specified levels.
Isolated spots where the surface levels deviate by more than 25 mm from the specified levels shall be
repaired to bring the deviation within the ± 20 mm tolerance.
(c) Layer thickness

The layer thickness shall be checked for compliance in accordance with Clause 10205.
The lot shall be deemed to comply with the requirements specified for layer thickness if at least 90% of
the thickness measurements taken before repairs are made is equal to or greater than the specified
thickness minus 27 mm, and the mean layer thickness of the lot is not less than the specified layer
thickness minus 5 mm.
(d) Width
The average width of the base shall be at least equal to that shown on the Drawings and nowhere
shall the outer edge of the base be more than 50 mm inside the edge lines shown on the Drawings.
(e) Cross Section

When tested with a 3 metre straightedge laid at right angles to the road centreline, the surface shall
not deviate from the bottom of the straightedge by more than 10 mm.
At any transverse section the difference in level between any two points shall not vary from their
difference in level computed from setting out data by more than 20 mm.

Pay Items 52.07 and 52.11 are applicable solely to work that has to be executed in a restricted area of
which the width is less than 3 m or the length is less than 150 m.
Item 52.01 Base layer construction

(a) Crushed-stone base compacted to:
3
(i) 98% of modified AASHTO density (Layer thickness indicated) ..... cubic metre (m )
3
(ii) 100% of modified AASHTO density (Layer thickness indicated) .. cubic metre (m )

(b) Natural Gravel base taken from cut or borrow (unstabilised gravel) compacted to:
(i) 98% of modified AASHTO density (Specify compacted layer thickness) .................
3
........................................................................................................cubic metre (m )
(ii) 100% of modified AASHTO density (Specify compacted layer thickness) ...............
3
....................................................................................................... cubic metre (m )
The unit of measurement shall be the cubic metre of completed gravel base or crushed-stone base in
place and compacted to the specified density. The quantity shall be calculated from the authorized
dimensions of the layer as shown on the Drawings or prescribed by the Engineer.
The tendered rates shall include full compensation for procuring, as if from soft excavation or pits;
supply from commercial sources or the Contractor’s crusher; haulage and transport; breaking down,
placing, compacting and finishing the layer including slushing operations for crushed stone bases;
removal and disposal of oversize material; the protection and maintenance of the layer; and the
conducting of control tests; all as specified.
The tendered rates shall also include full compensation for crusher fines or sand (if approved)
necessary for correcting the grading of the crushed stone and for crushing and screening.
3
Item 52.02 Extra over Pay Item 52.01 for excavation of hard material ........... cubic metre (m )
The unit of measurement shall be the cubic metre of material obtained from hard excavation as
defined in sub-clause 4204(b).
The tendered rates shall include full compensation for the additional costs involved for taking material
from classes of material harder than soft (normal) excavation and for the additional costs, if any, for
additional processing of such material in the pavement layers.
Item 52.03 Base layer constructed from material obtained from existing pavement layers
1. Crushed stone base material:
(a) Material compacted to 98% of modified AASHTO density: Material from existing uncemented
crushed-stone layers:
3
(i) Unscreened ....................................................................................cubic metre (m )
3
(ii) Screened and recombined in a plant ..............................................cubic metre (m )
(iii) Material from existing cemented crushed-stone layers, not milled but crushed,
3
screened and recombined in a plant ..............................................cubic metre (m )
(b) Material compacted to 100% of modified AASHTO density: Material from existing uncemented
crushed-stone layers:
3
(i) Unscreened ....................................................................................cubic metre (m )
3
(ii) Screened and recombined in a plant ..............................................cubic metre (m )
(iii) Material from existing cemented crushed-stone layers, not milled but crushed,
3
screened and recombined in a plant ..............................................cubic metre (m )
2. Gravel base material:
(a) Gravel base (unstabilised gravel) compacted to 98% of modified AASHTO density, using:
3
(i) Non-cemented material (Specify compacted layer thickness) ...... cubic metre (m )
3
(ii) Cemented material (Specify compacted layer thickness) ............. cubic metre (m )

(b) Gravel base (unstabilised gravel) compacted to 100% of modified AASHTO density using:
3
3
(ii) Cemented material (specify compacted layer thickness) ............. cubic metre (m )
The unit of measurement shall be the cubic metre of compacted pavement layer, the quantity of which
shall be calculated in accordance with the authorized dimensions of the completed layer if the
underlying layer has also been reconstructed or reworked. Where the underlying layer has not been
reconstructed or reworked but only rolled, or where no work has been done on it, quantities shall be
calculated with the aid of cross-sections taken of the layer before and after construction. Where the
material consist of recovered pavement material in part and imported material in part the quantity of
imported material shall be paid for under pay item 52.01, calculated in accordance with the volume
relation of the respective materials.
excavating the material in the existing pavement; procuring; haulage and transport; breaking down,
placing and compacting the material; protection and maintenance of the layer; and for the
performance of control tests; all as specified.
Where excavation is executed over sections of the road, payment shall also include compensation for
the proper measuring and marking-off of the excavation, and the protection of the adjacent existing
pavement and its repair should it be damaged.
The tendered rate for material from cemented layers shall include full compensation of breaking down
the material to comply with the specified grading requirements.
The tendered rates for material mixed with existing surfacing material shall also include full
compensation for breaking down fragments of bituminous material to the specified maximum size and
for removing over-sized fragments by hand.
Item 52.04 In-situ reconstruction of existing base layer

1. Uncemented Crushed stone base material:
3
(a) Material compacted to 98% of modified AASHTO density ......................... cubic metre (m )
3
(b) Material compacted to 100% of modified AASHTO density ...................... cubic metre (m )
2. Gravel base material:
(a) Gravel base (unstabilised gravel) compacted to 98% of modified AASHTO density, using:
3
3
(b) Gravel base (unstabilised gravel) compacted to 100% of modified AASHTO density using:
3
3
quantity of which shall be calculated in accordance with the authorized dimensions of the completed
layer.
The tendered rate shall include full compensation for breaking up the existing pavement layer to the
specified depth; breaking down and preparing the material; placing and compacting the material;
protection and maintenance of the layer; conducting control tests; measuring and demarcating the

work where layers are reprocessed partly; protecting the adjacent pavement; and its repair should it be
damaged.
material should the existing layer thickness be inadequate; as specified or as instructed by the
Engineer that the thickness shall be increased.
temporary blading of the in situ base material to windrow will be paid for under Pay item 52.06.
The tendered rate for cemented material shall include full compensation for breaking down the
material to comply with the specified grading requirements.
Item 52.05 Extra over Pay item 52.04 for adding extra material as specified below
3
(a) Gravel base ............................................................................................... cubic metre (m )
(b) Crusher fines for improving the grading of recovered crushed stone
3
(i) Material from approved borrow pits ............................................... cubic metre (m )
3
(ii) Material from commercial sources ..................................................cubic metre (m )
the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a
depth that will give a layer thickness of at least 100 mm after compacting together the loosened
existing and added material. In the case of gravel or crushed-stone bases the Engineer may direct the
existing layer to be broken down to its full depth.
The composite layer shall be watered mixed and compacted as determined in the clause for placing
and compaction. Payment for adding the material will be made as per this pay item.
The unit of measurement shall be a cubic metre of material added on the instruction of the Engineer
for gravel and crushed stone bases, which quantity shall be taken as 70% of the loose volume
measured in trucks, unless instructed by the Engineer that the quantity be determined by way of cross-
sections.
The tendered rate shall include full compensation for procuring, hauling and adding the material to the
in-situ broken-down pavement layer.
Item 52.06 Extra over Pay item 52.04 for temporarily blading the material to windrow .........
3
........................................................................................................... cubic metre (m )
The unit of measurement shall be a cubic metre of material from an existing pavement layer,
blading the material to windrow and later blading back and also for all clearing-up work which may be
necessary after the material has been bladed back.
layer shall be measured and paid for.
Material bladed or cut from restricted areas to windrow, and material temporarily stockpiled, will not be
paid for under this item.
restricted areas
3
(a) Non-cemented material .............................................................................. cubic metre (m )
3
(b) Cemented material...................................................................................... cubic metre (m )
excavated.
The tendered rate shall include full compensation for all additional costs for excavating the material in
restricted areas.
Item 52.08 Trial Sections

(a) Crushed-stone base trial section (thickness indicated) constructed in accordance with the
2
provisions of this Division ........................................................................square metre (m )
(b) Gravel base (unstabilised or chemically stabilised) trial section (thickness indicated)
2
constructed in accordance with the provisions of this Division .................square metre (m )
The unit of measurement shall be the square metre of completed trial section approved by the
Engineer.
The tendered rate shall include full compensation for constructing the trial section complete as
specified.
Only trial sections in which the base material and the completed layer comply with all the requirements
of the specifications shall be paid for.

Division 5300: Breaking up Existing Pavement Layers
5301 Scope
This section covers the breaking up and excavation of existing pavement layers by conventional
means or by milling; selecting the material; and the removal thereof to spoil dumps or to stockpiles for
later reprocessing or recycling.
5302 Selecting the Material

Material from existing pavements may only be used for purposes approved by the Engineer. The
material shall be so excavated that material from the various pavement layers will not be mixed unless
so permitted by the Engineer, in writing.
5303 Classifying the Material

Material from existing pavements shall be classified as follows for excavation and processing
purposes:
(a) Existing Bituminous Material

Existing bituminous material shall be asphalt or other bituminous seal or base material removed
separately from the existing layers on the instruction of the Engineer. Where underlying material is
broken down or excavated together with bituminous materials, the mixture will not be classified as
bituminous material for payment purposes.
(b) Non-Cemented Material

Non-cemented material shall be existing pavement material which can be ripped with the teeth of a
140G Caterpillar or similar grader.
(c) Cemented Material

Cemented material shall be existing pavement material, which cannot be ripped with the teeth 140G
caterpillar, or similar grader. Existing stabilised material will not necessarily be classified as cemented
material.
5304 Plant and Equipment
(a) General
The equipment to be used for the conventional breaking-up and excavation of existing pavement
layers will be determined by the size and depth of the pavement section to be processed or excavated,
taking into consideration that work may have to be carried out in restricted areas.
No additional pavement will be made for restricted areas.
Only approved cutting or sawing equipment may be used for cutting or sawing asphalt layers. The
equipment shall be capable of cutting the asphalt layers to the specified depth in one operation without
fragmenting the material, and in straight lines within the required tolerances.
(b) Milling Equipment

Only approved milling equipment may be used.
The equipment shall be capable of milling out asphalt and/or cemented material to the prescribed
depth in one operation over the width specified in the Particular Specifications or on the Drawings. The
milling depth shall be controlled electronically.
The direction and speed of the milling machine and the speed of rotation of the milling drum shall be
adjustable to obtain the required grading of the milled material.
The machine shall be capable of making a neat vertical cut at the outer edges when milling the layer
and to leave the floor of the cut level and with a uniform texture.
Unless otherwise specified in the Particular Specifications, the milling machine shall be equipped with
a self-loading conveyor belt, which can be easily removed, installed and adjusted for slope and
direction.
5305 Construction
(a) General
Where all or part of the existing surfacing material is to be reprocessed together with the underlying
layer, the surfacing shall be properly broken down and mixed through the full depth of the existing
base material to the satisfaction of the Engineer.
Fragments of bituminous material shall be broken down to sizes not exceeding 37.5 mm.
Where specified in the Particular Specifications or ordered by the Engineer, the existing bituminous
material shall first be removed before the underlying layers are broken up.
Bituminous material shall be milled out or otherwise broken up and removed to approved stockpile
sites for recycling or to spoil sites, whichever is required. Where the underlying material is to be
reprocessed as base, the exposed surface shall be cleaned to the satisfaction of the Engineer after
removal of the bituminous material. All remaining fragments of bituminous material shall be removed,
and not more than 5% of the surface may be covered with bituminous material.
The existing pavement material shall be broken down to the specified depth and removed, or
reprocessed in place, whichever may be required. The underlying layers may not be damaged, and
material from one layer may not be mixed with that of another layer. Where such mixing occurs or
where the material is contaminated in any other way by the actions of the Contractor, he shall remove
such material and replace it with other approved material.
Where a layer or layers require to be broken down over part of the pavement width only, the limit of the
work shall be clearly demarcated, which limit shall not be exceeded by the Contractor by more than
100 mm. Pavement layers broken down outside the specified limits shall be repaired at the
Contractor’s cost, to the satisfaction of the Engineer.
Where so ordered by the Engineer, asphalt and cemented layers shall be cut or sawn through to the
specified depth along the measured limit with approved equipment. Payment will be made for sawing
only where specified on the Drawings or ordered, in writing, by the Engineer.
Where existing roads have to be widened, the existing pavement layers shall be cut back to a firm,
well-compacted or cemented material. Material so broken up, if acceptable, may be used together with
imported material in the widening process, except in the case of crushed stone base. Where existing
pavement layers are widened, separate payment will not be made for cutting back into the existing
pavement layers unless so specified in the Particular Specifications, irrespective of the type of material
in the existing pavement layer.
Where pavement layers are broken down over a section of the road width; or where pavement layers
are widened; the Engineer may order, in writing, that the various pavement layers be excavated in
benches in accordance with his instructions. No additional payment will be made for excavating
benches.

(b) Milling
(i) General
The floor of the milled excavation shall be level and with an even texture without any loose patches or
patches of Unsuitable Material occurring.
Loose patches and patches with Unsuitable Material shall be remedied in accordance with the
instructions of the Engineer. Payment for removing and replacing unsuitable material and remedying
loose patches shall be as specified elsewhere in these specifications. Where such remedial work is
done in restricted areas, the extra over payment concerned shall be in accordance with the provisions
of the appropriate Clauses.
Where the floor of an excavation is tested in the longitudinal direction with a 3 m straight-edge; and in
other directions with a 3 m straight-edge or a straight-edge of such shorter length as fits in between
the longitudinal sides of the excavation; the surface shall not deviate by more than 7 mm from the
bottom edge of the straight-edge.
Payment for milling will distinguish between various milling depths.
(ii) Preparing the Pavement Surface

Before milling may be commenced, the pavement surface shall be clean and free from soil or other
deleterious material.
(iii) Trial Milling

Where ordered by the Engineer, the Contractor shall execute trial milling on the various materials to be
milled.
During the trial work, the Contractor will be expected to vary the direction and speed of the milling
machine, the speed of rotation of the milling drum, and also the milling depth, in order to obtain milled
material of the required grade.
(iv) Asphalt
Where the asphalt and/or the cemented base must be reused, the asphalt shall be removed
separately.
Where the asphalt consists of layers of various mixes or grades, the Engineer may instruct the
separate removal of the layers to different stockpiles.
Where the milled material is not conveyed directly by conveyor belt and then loaded, and the Engineer
so approves, the material shall first be cut to windrow and then loaded. During loading, the floor of the
excavation or the underlying material shall not be damaged.
The milled material shall be inspected and classified in accordance with the various types of asphalt
and its suitability for recycling.
Different stockpiles shall be used for the different types of material as ordered by the Engineer.
Contamination of the asphalt with underlying material will not be permitted, and the Contractor shall
adjust the depths of milling in accordance with the thickness of the layer.
(v) Cemented Material

Unless otherwise specified milled cemented material to be reprocessed on the road shall first be
windrowed with a view to inspecting the underlying surface for any patches of poor or unsuitable
material.
Where unsuitable material is encountered in the floor of the excavation, such material shall first be
removed by further milling (where the underlying layer also consists of the cemented material), or by
other approved methods, all to the satisfaction of the Engineer.

The unsuitable material shall be replaced with approved material of the required type, which shall be
placed in accordance with the specifications for the relevant underlying layer.
Where, in the opinion of the Engineer, the Contractor shall taper the ends or edges of a milled
excavation, payment will be made, provided that the tapering is not the result of defective work by the
Contractor. Any work deemed defective by the Engineer shall be repaired to the satisfaction of the
Engineer, at the Contractor’s cost.
5306 Storing Recovered Pavement Material

Excavated pavement material intended for reprocessing but which cannot be reprocessed in place; or,
in the opinion of the Engineer, cannot be windrowed next to the excavation, nor placed in position
directly at any other place; and material intended for recycling or reprocessing in a plant; shall be
transported to approved stockpiles with the written permission of the Engineer.
The stockpile site shall be cleaned, and all loose stones, vegetation and other materials which may
cause contamination, shall be removed.
The site shall be graded smooth with an adequate slope to ensure proper drainage of water. Where so
instructed by the Engineer, the surface of the site shall be watered and compacted to a depth of at
least 150 mm to a density of 90% of AASHTO T 180 maximum density. The compacted surface shall
be firm without any loose patches.
Where asphalt is recovered for recycling, the Engineer may order the surface to be chemically
stabilised to a depth of 150 mm. Upon completion, this surface shall be swept clean.
Stockpile sites shall be sufficiently large to allow the placing of stockpiles of different types of material
or types of recovered asphalt without the stockpiles overlapping or the limits of the prepared site being
exceeded. The enlargement of the stockpile site after the stockpiles have already been placed will not
be permitted without the approval of the Engineer.
Stockpiles of milled material shall be shaped in a manner, which will limit segregation to a minimum.
The stockpiling of asphalt shall be done in a manner that will limit consolidation to a minimum.
Adequate approved covers shall be provided for recovered asphalt stockpiles to prevent them from
becoming wet, or being contaminated by dust.
Upon completion of the work, the stockpile sites shall be broken up in accordance with the instructions
of the Engineer.
The stockpiling of excavated material will not be paid for directly, but full compensation thereof shall be
included in the rates for the various items of work in which the stockpiled material will be used.
Separate payment will be made for the preparation of storage sites.

(a) General
(i) Material to be Reprocessed

Direct payment will not be made for breaking up and excavating existing pavement material that is
reprocessed and re-used, except when:
 The material is milled out in accordance with the provisions of the project specifications or
upon the written instruction of the Engineer.

 Bituminous surfacing or other bituminous pavement layers are removed separately from the
underlying material in accordance with the Project Specifications or the written instructions of
the Engineer.
Full compensation for excavating existing pavement material, where the excavation thereof is not
payable separately, shall be included in the rates tendered for the various pavement layers and items
of work in which the material is used, as provided in the relevant specifications.
(ii) Removal of Bituminous Layers (except Milled Material)

Separate payment will be made for removing existing bituminous material separately from the
underlying layer, when it is not milled out in accordance with the project specifications or the
instructions of the Engineer, irrespective of whether or not it requires recycling.
(iii) Material from Existing Pavements which is not Reprocessed

Existing gravel pavement material, gravel, or existing bituminous material not intended for
reprocessing, shall be used for other specified purposes or taken to spoil. Payment for the excavation
of such material will be made directly under Pay Item 53.03 unless it is used for other purposes.
(iv) Milling
Milling will be paid for directly irrespective of whether or not the material will be re-used.
(v) Measurement for Excavating Existing Pavement Material and Underlying Fill
Where payment is made separately for the excavation of existing pavement material and underlying
fill, the quantity will be calculated in accordance with the authorized horizontal dimensions of the
excavated layer and the average depth of excavation. The average depth of excavation will be
determined in accordance with the test holes made or cores drilled at intervals not exceeding 10 m,
and which are so distributed over the surface that a realistic estimate of the depth can be obtained.
Item 53.01 Excavating and removing existing bituminous material (except milled material)
(a) Material intended for recycling with the average depth of excavation:
2
(i) Not exceeding 30mm ...................................................................square metre (m )
2
(ii) Exceeding 30mm but not exceeding 60mm....... ......................... square metre (m )
2
(iii) Exceeding 60mm .........................................................................square metre (m )
(b) Material to be disposed of with the average depth of excavation:

2
(i) Not exceeding 30mm ...................................................................square metre (m )
2
(ii) Exceeding 30mm but not exceeding 60mm ................................ square metre (m )
2
(iii) Exceeding 60mm .........................................................................square metre (m )
The unit of measurement shall be a square metre layer of bituminous material excavated from existing
pavements separately from the underlying material on the instruction of the Engineer, and removed to
approved stockpile or spoil sites.
The tendered rate shall include full compensation for determining the average thickness of the layer of
bituminous material to be excavated, including the excavation of holes or the drilling of cores, if so
instructed, for breaking down, excavating, loading, and transporting the material to approved
stockpiles or spoil sites and for loading and properly placing the material in stockpiles or spoil dumps.
The volume used for calculating overhaul shall be taken as 70% of the loose volume of the material
measured in the hauling vehicles.
Item 53.02 Milling out existing bituminous material with an average milling depth:
3
(a) Not exceeding 30mm .................................... ..............................................cubic metre (m )

3
(b) Exceeding 30mm but not exceeding 60mm................................................ cubic metre (m )
3
(c) Exceeding 60mm ..................................... ...................................................cubic metre (m )
The unit of measurement shall be a cubic metre of asphalt milled out and removed to approved
stockpile sites.
The tendered rate shall include full compensation for providing milling equipment and milling out the
material to the specified depth in accordance with the requirements for evenness and for all
measurements, labour, supervision and incidentals for executing the work and obtaining milled
material which will comply with the specified requirements.
The tendered rate shall also include full compensation for loading and transporting the material to
approved sites irrespective of the method of loading; for unloading the material and placing it in
stockpile; and for screening out the oversize material if necessary. Separate payment will be made for
preparing the stockpile site.
Payment for milling the material will distinguish between the various average depths of excavation,
irrespective of the required number of passes by the plant for milling out the material.
Item 53.03 Excavating and spoiling material from an existing pavement and/or the underlying
fill
3
(a) Non-cemented material....................................... ........................................cubic metre (m )
3
(b) Cemented material....................................... ...............................................cubic metre (m )
The unit of measurement shall be a cubic metre of material, with or without existing bituminous
material, excavated from the existing pavement and/or fill and removed to spoil dumps.
The tendered rate shall include full compensation for excavating the material from the existing
pavement and/or fill, irrespective of layer thickness, for loading, transporting, off-loading, and placing
the material in approved spoil dumps.
Payment will not distinguish between material with or without existing bituminous material.
Item 53.04 Sawing or cutting asphalt or cemented pavement layers

2
(a) Sawing asphalt ......................................... ................................................square metre (m )
(b) Cutting asphalt ........................................................ .............................................. metre (m)

2
(c) Sawing cemented material .......................................... ............................square metre (m )
The unit of measurement for sub-items (a) and (c) shall be the square metre of saw-cut area
calculated in accordance with the authorised length of saw-cut and the average saw depth measured
after excavation of the material. The unit of measurement for sub-item (b) shall be the metre of cut
measured in accordance with the authorised saw length.
The tendered rate shall include full compensation for all material and sawing or cutting costs and for all
incidentals for cutting or sawing the pavement in accordance with the instructions of the Engineer.
Payment will not distinguish between the various depths of sawing or cutting work, irrespective of the
number of separate cuts, which may be required for sawing or cutting the layer to the required depth.
Where surfacing of less than 30mm thickness is sawn together with a cemented pavement, the
surfacing section shall be deemed to be cemented material for payment purposes.

2
Item 53.05 Removing the remaining asphalt from the underlying layer .... square metre (m )
The unit of measurement shall be the square metre of excavation floor cleaned on the instruction of
the Engineer.
The quantity will be calculated in accordance with the authorised dimensions of the surface from which
the remaining bituminous material will have to be removed after the existing bituminous layer has been
taken off. Only surfaces of existing layers to be reprocessed as base will be paid for; and only if so
The tendered rate shall include full compensation for the removal of any remaining bituminous material
from the excavation floor as specified and the disposal thereof, all to the satisfaction of the Engineer.
2
Item 53.06 Preparing stockpile sites .................................................................. square metre (m )
The unit of measurement shall be the square metre of stockpile site prepared on the instruction of the
Engineer.
The tendered rate shall include full compensation for demarcating, clearing, levelling, watering,
compacting, and draining the stockpile site as specified.
Payment will not be made for preparing the sites for spoil dumps unless such preparation has been
instructed, in writing, by the Engineer.

Division 5400: Gravel Wearing Course and Gravel Shoulders
5401 Scope
This Division covers the specification of materials for, and the construction of, gravel wearing course
and gravel shoulders from natural gravels.
The gravel wearing course and gravel shoulders shall be constructed to the dimensions and cross
sectional profiles shown on the Drawings.
5402 Sources of Material

Gravel wearing course and gravel shoulder materials shall be obtained from approved sources in
excavations or borrow areas. The materials shall be located by the Contractor and approved by the
Engineer.
5403 Material Requirements for Gravel Wearing Course

The material shall consist of hard durable angular particles produced by crushing rock, crushing gravel
or from natural sources and shall be clean and free from organic matter, lumps of clay or other
deleterious substances.
The material shall be of such a nature that it can be readily laid and compacted without segregation.
The specifications are shown in Table 5403/1 and Table 5403/2
Table 5403/1: Material Specifications for Gravel Wearing Course
Property Specification Requirement Test Method

Maximum size (mm) 37.5 SANS 3001-AG1
Oversize index (Io) ≤5% Calculation based on SANS 3001-AG1
100 – 365
Shrinkage product (Sp) SANS 3001-GR10 for linear shrinkage
(max. of 240 preferable)
Grading coefficient (Gc) 16 – 34 Calculation based on SANS 3001-AG1
Soaked CBR (at 95% Mod
≥ 15 % SANS 3001-GR40
AASHTO compaction)
Treton impact value (%) 20 – 65 SANS 3001-AG9
Io = Oversize index (per cent retained on 37.5 mm sieve
Sp = Linear shrinkage x per cent passing 0.425 mm sieve
Gc = (Per cent passing 26.5 mm – per cent passing 2.0 mm) x per cent passing 4.75 mm)/100
Notes:
1: Specifications are applicable after placement and compaction
2: The Grading Modulus and Shrinkage Product must be based on a conventional particle size distribution determination
which must be normalised for 100% passing the 37.5 mm screen.
3: Only representative material samples are to be tested.
4: The Treton Impact Value (TIV) limits exclude those materials that are too hard to be broken with a grid roller (TIV < 20%)
or too soft to resist excessive crushing under traffic (TIV > 65%).

Table 5403/2: Material Specifications for Gravel Wearing Course for roads in ‘Urban or
Settlement’ Areas
Property Specification Requirement Test Method

Maximum size (mm) 37.5 SANS 3001-AG1
Oversize index (Io) 0 Calculation based on SANS 3001-AG1
Shrinkage product (Sp) 100 – 240 SANS 3001-GR10 for linear shrinkage
Grading coefficient (Gc) 16 – 34 Calculation based on SANS 3001-AG1
Soaked CBR (at 95% Mod
≥ 15 % SANS 3001-GR40
AASHTO compaction)
Treton impact value (%) 20 – 65 SANS 3001-AG9
Io = Oversize index (per cent retained on 37.5 mm sieve
Sp = Linear shrinkage x per cent passing 0.425 mm sieve
Gc = (Per cent passing 26.5 mm – per cent passing 2.0 mm) x per cent passing 4.75 mm)/100
5404 Construction Requirements for Gravel Wearing Course
(a) Equipment
Gravel wearing course and gravel shoulder material shall be spread by means of graders or other
equipment approved by the Engineer.
Gravel wearing course and gravel shoulder material shall be compacted by means of self-propelled or
towed steel wheeled rollers which are capable of achieving the density requirements stipulated in this
Clause.
Water shall be applied by means of equipment which is capable of distributing the applied water
uniformly over the surface of the layer.
(b) Oversize Material and Blending

If a significant portion of the gravel material is oversize, a portable crusher, or other suitable method as
instructed Engineer, shall be used to reduce the oversize to the maximum size specified. In some
cases, it may be economic to windrow the oversize material in or adjacent to the borrow pit and reduce
the oversize with a mobile hammer-mill (eg Rockbuster).
Although mobile hammer-mills can be used on material dumped on the road, it is recommended that
they be used in the borrow pit to reduce the transportation of oversized material.
If blending is necessary to achieve the specified shrinkage product or alter the particle size distribution
of the gravel, this shall be done in the borrow pit if the sources are in close proximity. Alternatively, the
mixing shall be done on the road with careful supervision of the dumping and mixing operations to
ensure the correct proportions of materials are thoroughly mixed to meet the specifications.
(c) Transport, Placing and Spreading

The material shall be transported in such a way, that no segregation occurs.
The material shall be placed, spread, broken down, watered if necessary and mixed in layers not
exceeding 200 mm and not less than 100 mm compacted thickness.
(d) Compaction
Prior to compaction, the moisture content of the spread material shall be adjusted as necessary either
by the uniform application of water or drying out, to achieve within -1% to +2% of the optimum
moisture content when determined in accordance with AASHTO T-180.
towards the centre of the road, except on superelevated curves, where the rolling shall begin at the

The in-situ density of the completed layer shall be 93% or 95% of the maximum dry density, as shown
on the Drawings, when determined in accordance with the requirements of AASHTO T-180 method D.
(e) Trial Areas

than 1000 square metres for gravel wearing courses and 250 square metres for gravel shoulder using
the materials and equipment proposed for the work to demonstrate compliance with the requirements
of this Clause.
5405 Construction Requirements for Gravel Shoulders

Where the shoulders are to be constructed from the same material as the base, they shall be
constructed simultaneously with the base.
In the case of crushed stone and asphalt bases, the shoulders shall be constructed after completion of
the base. Shoulder material shall be spread, broken down, watered, processed and compacted to a
density of not less than 93% or 95% of modified AASHTO density as specified in the Drawings, or as
instructed by the Engineer. The Contractor shall not start constructing the final bituminous surfacing of
any part of the road before he has completed the shoulders of such section to the approval of the
Engineer.

The completed gravel wearing course shall comply with the construction tolerances given below. The
tolerances shall be maximum permissible deviations from the specified dimensions, levels, alignment,
and positions shown on the Drawings or as given below:
(i) Level and Grade

The level tolerance shall be ± 25 mm.
Deviation from the specified longitudinal grade due to deviations from level shall not exceed the
tolerances in Table 5406/1.
Table 5406/1: Longitudinal Grade Tolerance
Length of Grade Measured in Maximum Variation from Specified

metre Grade (%)
2 0.34
5 0.27
10 0.21
20 0.13
30 0.08
(v)
(vi)
(ii) Width
The average total width of the wearing course and shoulders shall be at least equal to that shown on
the Drawings and nowhere shall the outer edge of the shoulders be more than 75 mm inside the edge
lines shown on the Drawings.
(iii) Thickness
The thickness tolerance shall be ± 30 mm.
(iv) Cross Section

When tested with a 3 metre straight-edge laid at right angles to the road centreline the surface shall
not deviate from the bottom of the straight-edge by more than 10 mm.
difference in level computed from the cross sections shown on the Drawings by more than 20 mm.
5407 Testing
The minimum testing frequency that will be required from the Contractor for the purpose of process
control shall be as shown in Table 5407/1

Frequency Minimum Number of
Test
(one test every) Tests/Lot
Material
2
Field Density and Moisture content 2 500 m 4
2
Atterberg Limits 2 500 m 4
Construction Tolerance
*
Surface Levels 20 m
*
Thickness 20 m
Width 200 m
Cross Section 20 m
2
Roughness 40 m
*
3 points per cross section
Note: The determination of field dry density expressed as a percentage of AASHTO T180 maximum dry density implies an
AASHTO T180 determination for each field density. Where material is homogeneous, this ratio can be decreased to
one laboratory density determination for up to four field densities.
The minimum dry densities given in Table 5407/2 shall be equalled or exceeded.
Table 5407/2: Density requirements:
Specified Density Number of Minimum Mean Density Minimum single value

(% of AASHTO T180 MDD) Tests/Lot (% of AASHTO T180 MDD) (% of AASHTO T180 MDD)
4 95.6 93.0
95 5 95.8 92.8
6 95.9 92.6
In calculating the mean, density values differing by more than five (5) percentage points from the
mean shall be disregarded and a new mean taken.
Any material or workmanship that does not comply with the specified requirements shall be removed
and replaced with material and workmanship complying with the specified requirements, or if the
Engineer permits, be repaired as specified in Clause 1208, so that after being repaired they will
comply with the specified requirements.
(i) Routine Inspection and Testing

Routine inspection and testing will be carried out by the Engineer to test the quality of materials and


Pay Items 54.06 and 54.10 are applicable solely to work that has to be executed in a restricted area of
which the width is less than 3m or the length is less than 150m.
Item 54.01 Gravel Wearing course and Shoulder constructed from gravel taken from cut or
borrow pits
(a) Gravel wearing course compacted to 93% or 95% of modified AASHTO density as required
3
(specify compacted layer thickness) ............................................................. cubic metre (m )
(b) Gravel shoulders wearing course compacted to 93% or 95% of modified AASHTO density
3
(specify compacted layer thickness) .............................................................. cubic metre (m )
The unit of measurement shall be the cubic metre of compacted pavement layer, and the quantity shall
be calculated from the authorised dimensions of the completed layer at the density specified on the
Drawings.
The tendered rates shall include full compensation for procuring material from soft (normal) excavation
or pits as defined in Clause 4204; breaking down; transport and haulage; placing, blading and
compacting the material; removal and disposal of oversize material; protection and maintenance of the
layer; and the conducting of control tests, all as specified.
Item 54.02 Gravel Wearing course and Shoulder constructed from non-cemented gravel
obtained from existing pavement layers
3
3
(specify compacted layer thickness) .............................................................. cubic metre (m )
The unit of measurement shall be the cubic metre of compacted layer, the quantity of which shall be
calculated in accordance with the authorised dimensions of the completed layer at the density
specified on the Drawings, when the underlying layer has also been reconstructed or reworked. Where
the underlying layer has not been reconstructed or reworked but only rolled, or where no work has
been done, quantities shall be calculated with the aid of cross-sections taken of the layer before and
after construction. Where the material consists of recovered pavement material in part and imported
material in part the quantity of imported material obtained from cut or borrow shall be paid for under
pay item 54.01, calculated in accordance with the volume relation of the respective materials.
excavating the material in the existing pavement; procuring; breaking down; transport and haulage;
placing, blading and compacting the material; protection and maintenance of the layer; and
performance of control tests, all as specified.
Where excavation is executed over sections of the road payment, the rate shall also include
compensation for the proper measuring and marking-off of the excavation, and the protection of the
adjacent existing pavement and its repair should it be damaged.
The use of cemented material in gravel wearing course and shoulders is not recommended.

Item 54.03 In-situ reconstruction of existing gravel wearing course and shoulder layer as
3
(specify compacted layer thickness) ............................................................ cubic metre (m )
3
quantity of which shall be calculated in accordance with the authorised dimensions of the completed
layer.
The tendered rate shall include full compensation for breaking up the existing layer to the specified
depth; breaking down and preparing the material; placing, blading and compacting the material;
protection and maintenance of the layer; conducting control tests; measuring and demarcating the
work where layers are reprocessed partly; protecting the adjacent pavement; and its repair should it be
damaged.
material should the existing layer thickness be inadequate, as specified, or instructed by the Engineer
that the thickness be increased.
temporary blading of the material to windrow will be paid for under pay item 54.05.
The use of cemented material in gravel wearing course and shoulders is not recommended.
Item 54.04 Extra over Pay item 54.03 for adding extra material as specified below
3
(a) Gravel wearing course ................................................................................... cubic metre (m )
3
(b) Gravel shoulder wearing course .................................................................... cubic metre (m )
the added material after compaction will be less than 100mm, the existing layer shall be scarified to a
depth that will give a layer thickness of at least 100mm after compacting together the loosened
existing and added material. In the case of gravel wearing courses, the Engineer may direct the
existing layer to be broken down to its full depth.
The composite layer shall be watered mixed and compacted as determined in the clause for placing
and compaction. Payment for adding the material will be made as per this pay item.
The unit of measurement shall be a cubic metre of material added on the instruction of the Engineer,
the quantity of which shall be determined from the cross-section.
The tendered rate shall include full compensation for procuring, transporting and adding the material
to the in-situ broken-down pavement.
Item 54.05 Extra over Pay item 54.03 for temporarily blading the material to windrow .........
3
........................................................................................................... cubic metre (m )
3
The unit of measurement shall be a cubic metre (m ) of material from an existing pavement layer,
blading the material to windrow or stockpiling and later blading back; and also for all clearing-up work
which may be necessary after the material has been bladed back.

layer shall be measured and paid for.
Material temporarily bladed or cut from restricted areas to windrow, including material temporarily
stockpiled, will be paid for under item 54.06.
3
restricted areas .................................................................................. cubic metre (m )
excavated.
The tendered rate shall include full compensation for all additional costs for excavating the material,
temporarily blading or cutting to windrows, or temporarily stockpiling in restricted areas.
The tendered rate shall include full compensation for all additional costs for compacting the pavement
excavation floor in a restricted area irrespective of the compaction plant used.

Division 5500: Hand-Packed Stone Paving and Mortared Hand-

Packed Stone Paving
5501 Scope
This Division covers all work in connection with laying and compacting of Hand-Packed Stone Paving
and Mortared Hand-Packed Stone Paving to lines, levels and dimensions as shown on the Drawings
and as directed by the Engineer.
Hand-Packed Stone Paving consists of a layer of large broken stone pieces, tightly packed together,
bedded on a layer of sand and wedged in place with smaller stone chips rammed by hand into the
joints using hammers and steel rods. The remaining voids are filled with sand or, in the case of
Mortared Hand-packed Stone Paving; the voids are filled with cement mortar. An edge restraint or kerb
constructed of large or mortared stones shall be provided.
5502 Materials
(a) Stones, Stone Chips and Kerb Stones

Stones shall be 175 mm to 225 mm in size on their longest axis and shall have a uniform texture with
ratios between dimensions of each stone in the range of 0.7:1. They shall consist of rock which is
hard, angular, and durable. The stones shall be free from vegetation, soft particles and excess clay or
any other deleterious substance.
The individual large stones shall comply with the following requirements:
 Water absorption < 2%;

 Los Angeles Abrasion value < 30%;
 Sodium Sulphate Soundness <10% loss.
Stone chips shall consist of hard, angular, durable stone having a maximum size of 50 mm.
Kerb-stones shall be 300 – 400mm on their longest axis and shall have a uniform texture with ratios
between dimensions of each stone in the range of 0.7 to 1. They shall consist of rock of similar quality
as the paving stones. One edge (upper) shall be flat.
(b) Blinding
Sand or gravel is required for the final blinding of the surface. This material shall be predominantly
fine, having a maximum particle size of 10 mm and a Plasticity Index less than 6.
(c) Bedding Material

Materials for the bedding layer shall consist of coarse sand of FM greater than 2.0 and a sand
equivalent value (SEV) of greater than 70. It shall have a grading envelope as shown in Table 5502/1.
Table 5502/1: Bedding Material Gradation

ISO Sieve Size (mm) % Passing
9.5 100
4.75 95 - 100
2.0 80 - 100
1.0 50 - 85
0.6 25 - 60
0.3 10 - 30
0.15 5 - 15
0.075 0 - 10

(d) Cement-Mortar
Mortar ingredients shall conform to the standard requirements for Portland cement, admixtures and
water, masonry cement to ASTM C91 and fine sand Aggregate to AASHTO M45. The material shall be
clean and free from clay coating, organic debris and other deleterious materials. The mortar cube
strength shall be not less than 7.5 MPa.
The proportions shall be such that the volume of sand in a damp loose condition is between two (2)
and three (3) times the volume of cementitious materials. The cementitious materials shall consist of
one (1) part Portland cement to between one (1) and two (2) parts of masonry cement. Pre-mixed
materials conforming to these requirements may be used.
5503 Construction Equipment

The following construction equipment shall be used:
 Light vibrating roller or plate compactor;

 Concrete mixer of at least 80 litre mix capacity.

Prior to laying the bedding material, the Contractor shall correct any deformations, ruts, soft spots or
other defects in the formation or sub-base to the satisfaction of the Engineer.
All drainage works necessary to keep the road formation and pavement layers free of standing water
shall be completed before construction commences. Any edge restraints specified such as kerbs,
shoulders or mortared stone edge constraints shall be constructed in advance to a thickness
corresponding to the compacted layer of the stone.
Traffic shall be prevented from crossing the works until the bedding sand and any covering layer have
been completed.
Bedding sand shall be compacted to a thickness of 50 mm with one pass of a vibrating plate
compactor or vibrating roller.
Before placing the stones, guiding string lines shall be placed using metal pegs made of reinforcement
steel to indicate the finished layer level. The peg interval shall be 5 metres. Lines shall be placed
longitudinally, transversely across the road, and diagonally, to indicate the desired camber.
Stones shall be placed from the edges of the road against the kerbstones towards the centreline. The
longest axis or the second longest axis shall be vertical. The largest stones shall be used along the
edge of the pavement with a row of stones along the centreline, before placing the rest of the stones.
The stones shall be placed to the required grades and camber.
Individual stones shall be laid to have contact with each other and must bed into the sand bedding
without any support from the adjacent stones. Each stone must be tapped firmly into the final position
with a hammer. The residual thickness of the bedding layer underneath the stone blocks shall not be
less than 30mm.
Voids between the stones shall be filled with stone chips packed in with a hammer. After packing the
gaps with stone chips, the blinding layer shall be spread and gently washed and brushed into the
voids between the stones.
A vibrating roller or a plate compactor or other approved roller shall be used for compaction which
should be carried out to level the height of the stone blocks, providing a smooth running surface on the
carriageway. Compaction shall be carried out from the edge to the centreline of the road.

For Hand-packed Stone Paving, after final compaction of hand-pack stone paving, the road shall be
allowed to dry out for a period of at least 24 hours. Any areas of looseness shall be reworked to the
For Mortared Hand-packed Stone Paving, after packing the gaps between the large stones with
broken stones, cement mortar shall fill the remaining voids as necessary and be finished level to
provide a smooth surface.
Once the mortar has set, the paving shall be cured by spreading sand or sacking over the surface of
the pavement and repeatedly wetting the materials for a period of at least 7 days and no traffic shall be
allowed on the pavement during this period. The Engineer may direct a longer curing period
depending on local circumstances.
5505 Laboratory & Site Testing
(a) General
The Engineer shall exercise control over quality of the materials incorporated and works performed
through quality control tests carried out to the frequencies indicated in Table 5505/1. The frequencies
are the minimum required, and the Engineer shall have the authority to have these tests undertaken at
more frequent intervals where the quality of a material or work is in doubt.
Materials from each source shall be submitted to the Engineer for approval in advance of the
commencement of work.
(b) Laboratory Testing
Table 5505/1: Laboratory Tests

Frequency of Test
Test
(one test every)
Stone
Los Angeles Abrasion 1.0 km and at each change of material source or character
Water Absorption 1.0 km and at each change of material source or character
Sodium Sulphate Soundness 1.0 km and at each change of material source or character
Bedding and Blinding Material
Atterberg Limits 1.0 km and at each change of material source or character
Grading 1.0 km and at each change of material source or character
One set of 3 mortar cubes (70 mm) per material source or
Mortar cube strength
character change
(c) Site Testing

Visual Inspection of operations will be made to check compliance with the Drawings and
Specifications.
A pavement layer quality and specification compliance inspection will be undertaken on all completed
sections of the stone paving layer by the Engineer prior to acceptance of the Works.
Table 5505/2: Site Inspection Criteria

Criteria Measurement Tolerance
Pavement width By tape every 300m ± 25 mm
Pavement thickness Inspection pit every 500m ± 15 mm
Crossfall Measure with straight edge and bubble – every 300m Within 2% of specification
The maximum clearance to a 2 m straight edge laid at an orientation across the pavement shall be
15 mm to the centre of the stone at any point.


Item 55.01 Hand-packed Stone Paving

2
(a) Unmortared Hand-Packed Stone Paving (150 mm; 200 mm or 250mm) .. square metre (m )
2
(b) Mortared Hand-Packed Stone Paving (150mm; 200 mm or 250mm) ........ square metre (m )
Hand-packed stone paving and mortared hand-packed stone paving shall be measured by the square
metres of placed stone layering on the road. The quantity for which payment shall be made shall be
the product of the instructed average width (including edge restraints/kerbs) and the measured length
along the centreline of the road.
The tendered rate shall include the general requirements of Series 0000 and the following specific
requirements:
 Setting, bedding, jointing, coursing, raking, forming quoins, grouting, pointing, and fair face
work including rough and fair cutting;
 Bedding layers but excluding road bases;
 Blinding
 Temporary supports;
 Bonding into existing work;
 Building in pipes, holdfasts, bolts and the like and forming small openings;

DIVISION 5600 Stone Setts and Cobblestone Paving
5601 Description
This Division covers all work in connection with laying stone setts and cobblestones being laid to lines,
levels and dimensions as shown on the Drawings or as directed by the Engineer.
5602 Materials
(a) Stone Setts

The stone setts shall be hard, homogenous, isotropic rock, free from significant discontinuities such as
cavities, joints, faults and bedding planes. It shall be in a fresh condition, free from deleterious
inclusions, and not susceptible to weathering, degradation or significant strength deterioration on
exposure.
The rock should have the following mechanical properties:
 Soaked unconfined compressive strength >75MPa

 Los Angeles Abrasion value: <25%
 Sodium Sulphate Soundness <10% loss
Stone setts should be roughly cubic in shape and typically 100 mm thick. The individual setts should
have at least one face that is reasonably flat and suitable to be the upper surface.
(b) Dressed Stones and Cobblestones

Dressed Stones and Cobblestones shall be a strong, homogenous, isotropic rock, free from significant
discontinuities such as cavities, joints, faults and bedding planes. It shall be in a fresh condition free
from deleterious inclusions, and not susceptible to weathering, degradation or significant strength
deterioration on exposure.
The rock shall have the following mechanical properties:
 Soaked unconfined compressive strength: >75MPa

 Los Angeles Abrasion value: <25%
 Sodium Sulphate Soundness: <10% loss
Dressed Stones shall be typically 300 mm x 200 mm x 100 mm in size and the Cobblestones typically
150 mm cubes (or other dimensions approved by the Engineer). The stones shall be regular and
uniform in shape and texture with sharp square edges and parallel faces. They shall normally be hand
cut from solid rock and trimmed (dressed) if necessary to form a regular rectangular shape, free from
flaws and discontinuities.
(c) Blinding
The material infilling the spaces between the stones shall be loose, dry natural or crushed stone
material with a grading equivalent to well-graded, coarse sand to fine gravel. The material shall be
clean and free from clay coating, organic debris and other deleterious materials.
(d) Sand Bedding

Materials for the bedding layer shall consist of coarse sand of FM greater than 2.0 and a sand


9.5 100
4.75 95 - 100
2.0 80 - 100
1.0 50 - 85
0.6 25 - 60
0.3 10 - 30
0.15 5 - 15
0.075 0 - 10
(e) Cement Mortar

clean and free from clay coating, organic debris and other deleterious materials. The mortar cube
strength shall be not less than 7.5 MPa.
The proportions shall be such that the volume of sand in a damp loose condition is between two to
three times the volume of cementitious materials. The cementitious materials shall consist of one part
Portland cement to between one and two parts of masonry cement.

 1 Tonne vibrating roller.

 60 Kg Plate Compactor
 Concrete mixer of at least 80 litre mix capacity (Mortar Option)
(a) Standard Procedure (Sand-Joints)

shall be completed prior to laying stones. The Contractor shall establish temporary screeding rails to
ensure that the final shape of the layer conforms to the Drawings. Cement mortar bedded and jointed
pavement edge stones or kerbs shall be placed first.
Sand bedding materials shall be dumped on the prepared formation in such a manner as to allow for
continuity of operations over the length of the formation. Spreading of the sand material shall be by
manual methods to slightly above the screed levels. The relationship between the loose thickness and
compacted thickness shall be determined from trials and used in controlling the loose thickness at the
time of spreading the materials. The sand will then be lightly compacted with a vibrating plate
compactor or vibrating roller. Screeding boards will be used to remove the excess sand and level it to
the correct profile giving the final thickness of 50mm, or as shown on the Drawings
Delivered stone setts, dressed stone or cobblestones shall be stacked on, or adjacent to, the prepared
formation in such a manner as to allow for continuity of operations, avoid damage to the stones and to
cause least inconvenience and danger to traffic.
Stone setts, dressed stones and cobblestones shall be laid on the previously prepared sand bedding
layer. All stones shall be placed with the smoothest face uppermost. The Contractor shall establish
sufficient setting out pegs and string lines to ensure that the final shape of the stone sett layer confirms
with the Drawings, which shall be checked with a camber board, or straight edge, spirit level and tape.
Each stone shall be lightly tapped into position with a mason’s hammer, to ensure initial bedding.
String-lines shall be used as a guide for finished crossfall and level of the surface. Spaces between
stones should not exceed 10mm. These spaces shall be in-filled by brushing in the specified sand-
gravel material. When a small area of stones is in place they should be consolidated in position with a
small vibrating roller or plate compactor. Additional infill materials should be brushed into the surface
as required. Following light and even sprinkling of water the final rolling shall be carried out by a
minimum 1 Tonne vibrating roller with 6-8 passes.
All extraneous matter or damaged stones shall be removed and made good with new material to the
full thickness of the layer.
(b) Mortared Option

The construction procedure for the mortared option is similar to the standard procedure except that the
stones shall be laid on a 20-25 mm cement mortar bed on the pre-prepared and approved road base
within edge restraints, as specified above. Joints shall be filled as necessary with cement mortar to the
finished level with the top face of the stone to provide a smooth finished surface.
(a) General
through quality control tests carried out to the frequencies indicated here in under. The frequencies are
the minimum, and the Engineer shall have the authority to have these tests undertaken at more
frequent intervals, where quality of a material or work is in doubt.
Materials from each source should be submitted to the Engineer for approval in advance of the
commencement of work.
Table 5605/1: Laboratory Testing

Frequency of Test
Test
(one test every)
Stone
Los Angeles Abrasion 1.0 km and at each change of material source or character
Water Absorption 1.0 km and at each change of material source or character
Sodium Sulphate Soundness 1.0 km and at each change of material source or character
Bedding and Jointing Material
Cement Mortar
character change
(c) Site Testing

Specifications.


The upper face of individual stones shall be generally smooth and checked by 2 metre straight edge
for overall paving surface variation. The maximum clearance to a 2 m straight edge laid at any
orientation across the pavement shall be 10 mm to the centre of the stone at any point.
5606 Measurement and payment

Item 56.01 Stone Sett, Dressed Stones and Cobblestones Paving

2
a) Stone Sett, Dressed stones and Cobblestones Paving ................................ square metre (m )
2
b) As in item 56.01 (a) – Mortared Option ........................................................ square metre (m )
Stone sett, dressed stone or cobblestone surfacing shall be measured by the square metres of placed
and interlocked or mortared stone layering on the road. The quantity of work will be calculated by
measurement of the width (including edge restraints/kerbs) and approved length of the road,
measured along the centreline of the road, taking into account the depth of the compacted layer.
requirements:
 Blinding material;

Division 5700 Fired Clay Brick Pavement
5701 Scope
This Division covers all work in connection with providing, laying and placing a layer of on-edge-on
bricks within edge constraints to lines, levels and dimensions as shown on the Drawings or as directed
by the Engineer.
5702 Materials
(a) Fired Clay Bricks

The raw material for brick manufacture shall be a sandy clayey silt or silty clay of low to medium
plasticity. The material shall be uniform and comprise a relatively high proportion of silica (quartz)
minerals. It must also be free from significant quantities of deleterious materials such as combustible
vegetable matter, mica minerals and salts.
The fired bricks shall be of Engineering standard with the following characteristics:-
 Dimensions: 200x100x70 mm (or as agreed by the Engineer)

 Dimensional Tolerance: ± 3%
 Water absorption: <16% of their weight of water after 1 hour soaking
 Unit weight: >1200 kg/m3
 Crushing strength: >20MPa
The bricks shall be solid, regular and uniform in shape and texture with sharp square edges and
parallel faces. They shall be free from flaws, chips, stones and blemishes and shall emit a clear
metallic ring when struck against each other.
(b) Joint in-fill

The material infilling the spaces between the stones shall be loose, dry, natural or crushed stone
material with a grading equivalent to a well graded coarse sand to fine gravel. The material shall be
clean and free from clay coating, organic debris and other deleterious materials.
(c) Sand Bedding

Material for the bedding layer shall consist of coarse sand of FM greater than 2.0 and a sand

9.5 100
4.75 95 - 100
2.0 80 - 100
1.0 50 - 85
0.6 25 - 60
0.3 10 - 30
0.15 5 - 15
0.075 0 - 10
(d) Cement Mortar

clean and free from clay coating, organic debris and other deleterious materials. The cube strength
shall be not less than 7.5 MPa.
The proportions shall be such that the volume of sand in a damp loose condition is between two to
three times the volume of cementitious materials. The cementitious materials shall consist of one part
Portland cement to between one and two parts of masonry cement.

 60 Kg Plate Compactor
 Concrete mixer of at least 80 litre mix capacity (Mortar Option)
5704 Construction
(a) Standard Procedure (Sand Joints)

shall be completed. The Contractor shall establish temporary screeding rails to ensure that the final
shape of the layer conforms to the Drawings. Cement mortared brick pavement edges or kerbs shall
be placed prior to laying the bricks.
Sand materials shall be dumped on the prepared formation in such a manner as to allow for continuity
of operations over the length of the formation. Spreading of the sand material shall be by manual
methods to slightly above the screed levels. The relationship between the loose thickness and
compacted thickness shall be determined from trials and used in controlling the loose thickness at the
time of spreading the materials. The sand shall then be lightly compacted with a vibrating plate
compactor or vibrating roller. Screeding boards shall be used to remove the excess sand and level it to
the correct profile giving the final thickness of 25mm, or as shown on the Drawings.
The Contractor shall establish sufficient setting out pegs and string lines to ensure that the final shape
of the brick layer conforms to the Drawings.
Delivered bricks shall be stacked on or adjacent to the prepared formation in such a manner as to
allow for continuity of operations, avoid damage to the bricks and to cause least inconvenience and
danger to traffic.
The bricks shall be laid on edge (100 mm depth) over the bedding within edge restraints, as detailed
on the Drawings and as required by the Engineer. The Contractor shall establish sufficient setting out
pegs and string lines to ensure that the final shape of the paving conforms with the Drawings.
The bricks shall be laid in a herring bone or other approved pattern. Joint width between bricks shall
be between 5 mm and 10 mm. Filling sand shall be spread over the placed bricks, and brushed into
the joints. The laid paving shall then be compacted with a vibrating plate compactor to properly bed
the bricks and key the joint sand securely between the bricks. Joints shall be refilled as necessary to
achieve full joints and satisfactory interlock between the bricks.
All extraneous matter or defective bricks shall be removed and made good with new material to the full
thickness of the layer.
(b) Mortared Option

The construction procedure for the mortared option is similar to the standard procedure except that the
bricks shall be laid on edge (100 mm depth) on a 20-25 mm cement mortar bed on the pre-prepared

and approved road base within edge restraints, as detailed on the Drawings. Joints shall be filled as
necessary with cement mortar to achieve satisfactory bond between the bricks. Joints will be finished
level with the top face of the bricks to provide a smooth finished surface.
(a) General
through quality control tests carried out to the frequencies indicated here in under. The frequencies are
the minimum. The Engineer shall have the authority to have these tests conducted at more frequent
intervals, where quality of a material or work is in doubt.

The following laboratory testing shall be undertaken
Table 5605/1: Laboratory Testing
Frequency of Test
Test
(one test every)
Bricks
2 sets of 5 per material source (more frequently if material
Density of bricks
character changes) ) and one per km of road
Compressive strength of bricks As above
Water Absorption of the bricks As above
Bedding and Joint Material
Cement Mortar
character change
(c) Site Testing

specifications.

Brick Dimensions Sample of 10 from each 1km ± 3%
The maximum clearance to a 2 m straight edge laid at any orientation across the pavement shall be 10
mm to the centre of a brick at any point.


Item 57.01 Fired Clay Brick Paving

2
a) Fired Clay Brick Paving ................................................................................. square metre (m )
2
b) Fired Clay Brick Paving – Mortared Joints .................................................... square metre (m )
Mortared clay brick surfacing shall be measured by the square metres of placed sand-jointed or
mortared brick layering on the road. The quantity for which payment shall be made shall be the
product of the instructed average width (including edge restraints/kerbs) and the measured length
requirements:
 Binding material;

Series 6000: Bituminous Surfacings and Road Base
TABLE OF CONTENTS
DIVISION 6100 – BITUMINOUS PRIME COAT ........................................................................................... 343
6101 Scope ........................................................................................................................................ 343
6102 Materials ................................................................................................................................... 343
(a) Priming material ............................................................................................................................ 343
(b) Mineral Aggregate for Blinding .................................................................................................... 343
6103 Safety ........................................................................................................................................ 344
6104 Equipment................................................................................................................................. 344
6105 Weather and Other Limitations ................................................................................................. 344
6106 Storage of Prime Coat Material ................................................................................................ 345
6107 Preparation of the Layer to be Primed ..................................................................................... 345
6108 Application of the Prime Coat ................................................................................................... 346
6109 Maintenance and Opening to Traffic......................................................................................... 346
6110 Tolerances ................................................................................................................................ 347
6111 Testing ...................................................................................................................................... 347
DIVISION 6200 – TACK COAT ................................................................................................................ 348
6201 Scope ........................................................................................................................................ 348
6202 Materials ................................................................................................................................... 348
(a) Tack coat material ......................................................................................................................... 348
(b) Water for the Production of Bitumen Emulsion ............................................................................ 348
6203 Equipment................................................................................................................................. 348
6204 Weather and Other Limitations ................................................................................................. 348
6205 Storage of Tack Coat Material .................................................................................................. 349
6206 Surface Preparation .................................................................................................................. 349
6207 Application of the Tack Coat ..................................................................................................... 349
6208 Traffic ........................................................................................................................................ 350
6209 Tolerances ................................................................................................................................ 350
6210 Testing ...................................................................................................................................... 350

DIVISION 6300: SURFACE SEALS ........................................................................................................... 351
6301 Scope ........................................................................................................................................ 351
6302 Health and Safety ..................................................................................................................... 351
6303 Materials.................................................................................................................................... 351
(a) Bituminous Binders ....................................................................................................................... 351
(i) Selection of Bituminous Binders .............................................................................................................. 352
(ii) Penetration Grade Bitumen (Based on SANS 4001-BT1) ........................................................................ 352
(iii) Cutback Bitumen (Based on SANS 4001-BT2, previously SANS 308) ................................................... 352
(iv) Bitumen Emulsions (also called emulsified asphalts) ............................................................................... 353
Modified Binders (based on TG1, 3rd edition, 2014 from SABITA) ................................................................... 353
Requirement for Rubber Crumb for modified bitumens (based on the prevailing version of TG1 from SABITA)
............................................................................................................................................................................. 355
(b) Aggregate Chippings for Surface Seals ......................................................................................... 355
(i) Grading and Flakiness ............................................................................................................................... 355
(ii) Strength, Abrasion and skid resistance ...................................................................................................... 356
(iii) Bitumen Affinity and adhesion ................................................................................................................. 359
(iv) Pre-coating of Aggregate .......................................................................................................................... 359
(v) Chipping Size and Application Rate ......................................................................................................... 359
(c) Sand for Surface Seals ...................................................................................................................360
(d) Slurry Seals ...................................................................................................................................360
(i) Aggregate Gradings for Slurry Seals ........................................................................................................ 360
(ii) Cement Filler for Slurry Seal .................................................................................................................... 361
6304 Plant & Equipment .................................................................................................................... 361
(a) General ..........................................................................................................................................361
(b) Bitumen Distributor....................................................................................................................... 361
(i) Depot Spray Test ....................................................................................................................................... 363
(c) Water Sprinkler ............................................................................................................................. 364
(d) Mechanical Sweepers or Broom ....................................................................................................364
(i) Drag Brooms ............................................................................................................................................. 364
(ii) Rotary Brooms .......................................................................................................................................... 364
(e) Air blowers ....................................................................................................................................364
(f) Chip Spreaders .............................................................................................................................. 364
(g) Rollers ...........................................................................................................................................364
(i) Pneumatic-tyred Rollers ............................................................................................................................ 364
(ii) Rubber-soled Flat Rollers ......................................................................................................................... 365

(iii) Steel-tyred Flat Rollers ............................................................................................................................. 365
(h) Trucks for Transportation of Chippings ........................................................................................ 365
(i) Mixer for Slurry Seal .................................................................................................................... 365
(j) Spreader Box for Slurry Seal ........................................................................................................ 365
(k) Pre-coating Plant ........................................................................................................................... 366
(l) Weighing Devices ......................................................................................................................... 366
(m) Miscellaneous Equipment ............................................................................................................. 366
(n) Reserve Equipment ....................................................................................................................... 366
6305 Limitations and General Requirements .................................................................................... 366
(a) Stockpiling of Aggregates ............................................................................................................. 366
(b) Weather limitations ....................................................................................................................... 366
(c) Moisture Content .......................................................................................................................... 367
(d) Curing Periods for Slurry Seals..................................................................................................... 367
(e) Spraying to cease at 15:00 hours ................................................................................................... 368
(f) Traffic............................................................................................................................................ 368
(g) Trial Areas ..................................................................................................................................... 368
(h) Cutting Back of Bitumen .............................................................................................................. 368
(i) Heating of Conventional Bituminous Binders .............................................................................. 368
(j) Heating of Modified Bituminous Binders ..................................................................................... 369
(k) Preparation of Areas to be Surfaced .............................................................................................. 369
(i) General ..................................................................................................................................................... 369
(ii) New Construction ..................................................................................................................................... 369
(iii) Existing surfaces that are to be resurfaced ................................................................................................ 369
(l) Demarcation of Working Area ...................................................................................................... 370
(i) New Construction ..................................................................................................................................... 370
(ii) Existing surfaces that are to be resurfaced ................................................................................................ 370
(m) Protection of Kerbs, Channels etc. ................................................................................................ 370
(n) Dust Control .................................................................................................................................. 370
6306 Construction.............................................................................................................................. 370
(a) General .......................................................................................................................................... 370
(b) Application of Binders .................................................................................................................. 370
(c) Joints between Binder Sprays ....................................................................................................... 370
(d) Application of Chippings .............................................................................................................. 371
(e) Rate of application to be determined by the Engineer .................................................................. 371
(f) Single and double surface treatment – General Requirements ...................................................... 371

(i) First application of binder and chippings .................................................................................................. 371
(ii) Initial Rolling of Chippings ...................................................................................................................... 371
(iii) Broom Drag and Final Rolling of Chippings ............................................................................................ 372
(g) Fog Spray ......................................................................................................................................372
(h) Blinding .........................................................................................................................................372
6307 Rates of Application .................................................................................................................. 372
6308 Areas Inaccessible to Mechanical Equipment .......................................................................... 373
(a) Prime coat/Tack coat ..................................................................................................................... 373
(b) Binders for Surface Seals ..............................................................................................................373
(c) Aggregate Chippings ..................................................................................................................... 373
(d) Slurry .............................................................................................................................................373
(e) Bituminous Mixture ...................................................................................................................... 374
6309 Opening to Traffic ...................................................................................................................... 374
6310 Defects ...................................................................................................................................... 374
(a) Surface Defects ............................................................................................................................. 375
(i) Treatment Type 1 ...................................................................................................................................... 375
(ii) Treatment Type 2 ...................................................................................................................................... 375
(iii) Treatment Type 3 ...................................................................................................................................... 375
(b) Bleeding ........................................................................................................................................376
(i) General ...................................................................................................................................................... 376
(ii) Method 1: Single seal with slurry: Light bleeding .................................................................................... 376
(iii) Method 2: Single seal with slurry: Severe bleeding .................................................................................. 376
(iv) Method 3: Bleeding single or multiple seals ............................................................................................. 376
(c) Loss of Aggregate.......................................................................................................................... 377
(i) Slight loss of aggregate ............................................................................................................................. 377
(ii) Loss of aggregate in limited areas due to low temperature ....................................................................... 377
(iii) Loss of aggregate in large areas due to low temperature .......................................................................... 377
(iv) Loss of Aggregate in areas due to binder deficiency................................................................................. 377
6311 Maintenance ............................................................................................................................. 377
6312 Damage to the Road Surface by Third Parties ......................................................................... 377
6313 Tolerances and Finish Requirements ....................................................................................... 378
(a) New Construction .......................................................................................................................... 378
(i) General ...................................................................................................................................................... 378
(ii) Level and Grade ........................................................................................................................................ 378

(iii) Width ........................................................................................................................................................ 378
(iv) Cross Section ............................................................................................................................................ 378
(v) Surface Regularity .................................................................................................................................... 378
(b) Resealing Work on Existing Surfaces ........................................................................................... 378
(c) Rate of Application ....................................................................................................................... 378
6314 Testing ...................................................................................................................................... 379
(b) Routine Inspection and Testing ..................................................................................................... 379
6315 Single Surface Seals ................................................................................................................ 379
(a) Materials ....................................................................................................................................... 379
(b) Construction .................................................................................................................................. 380
(i) Application of Binder and Chippings ....................................................................................................... 380
(ii) Initial rolling ............................................................................................................................................. 380
(iii) Final rolling .............................................................................................................................................. 380
(iv) Fog Spray.................................................................................................................................................. 380
(v) Blinding .................................................................................................................................................... 380
(vi) Pre-coating of Chippings .......................................................................................................................... 380
(vii) Work in Areas Inaccessible to Mechanical Equipment .................................................................. 380
(c) Opening to Traffic ......................................................................................................................... 380
6316 Double Surface Seals ............................................................................................................... 380
(a) Materials ....................................................................................................................................... 381
(b) Construction .................................................................................................................................. 381
(i) Application of the First Layer ................................................................................................................... 381
(ii) Application of the Second Layer .............................................................................................................. 381
(iii) Initial Rolling ............................................................................................................................................ 382
(iv) Broom Drag and Final Rolling of Aggregate ............................................................................................ 382
(v) Fog Spray.................................................................................................................................................. 382
6317 Triple Seal Surface Treatment .................................................................................................. 382
(a) Materials ....................................................................................................................................... 382
(b) Construction .................................................................................................................................. 382
(i) Application of the First Layer ................................................................................................................... 382
(ii) Application of the Second and Third Layers ............................................................................................ 383
(iii) Initial Rolling of the Second and Third Layers ......................................................................................... 383

(iv) Broom drag and Final Rolling of the Second and Third Layers ............................................................... 383
(v) Fog Spray .................................................................................................................................................. 383
6318 Single Surface Treatment with Slurry (Cape Seal) ................................................................... 383
(a) Materials ........................................................................................................................................384
(i) Chippings .................................................................................................................................................. 384
(ii) Binder for First Application ...................................................................................................................... 384
(iii) Binder for Second Application .................................................................................................................. 384
(iv) Binder for Slurry ....................................................................................................................................... 384
(b) Construction before Application of Slurry ....................................................................................384
(c) Application of First Layer of Binder and Chippings .....................................................................384
(i) Initial Rolling ............................................................................................................................................ 384
(ii) Broom Drag and Final Rolling of Aggregate ............................................................................................ 384
(d) Second Application of Bituminous Binder ....................................................................................385
(e) Application of Slurry ..................................................................................................................... 385
(i) Condition of Surface ................................................................................................................................. 385
(ii) Timing of Slurry Application .................................................................................................................... 385
(iii) Composition of Slurry............................................................................................................................... 385
(iv) Mixing of Slurry ....................................................................................................................................... 385
(v) Application of Slurry ................................................................................................................................ 386
6319 Sand Seals ................................................................................................................................ 387
(a) Materials ........................................................................................................................................387
(i) Binders ...................................................................................................................................................... 387
(ii) Sand .......................................................................................................................................................... 387
(b) Construction ..................................................................................................................................387
(i) Equipment ................................................................................................................................................. 387
(ii) Preparation of surface before application of seal ...................................................................................... 387
(iii) Application of sand seal ............................................................................................................................ 387
6320 Graded Aggregate Seals........................................................................................................... 388
(a) Materials ........................................................................................................................................388
(i) Binders ...................................................................................................................................................... 388
(ii) Kerosene for cutting back bitumen ........................................................................................................... 388

(iii) Anti-stripping agent .................................................................................................................................. 388
(b) Aggregates for Otta Seals ............................................................................................................. 389
(i) Grading ..................................................................................................................................................... 389
(ii) Aggregate strength .................................................................................................................................... 389
(iii) Flakiness Index ......................................................................................................................................... 390
(iv) Sand for cover seals .................................................................................................................................. 390
(c) Aggregates for Other Graded Seals ............................................................................................... 390
(d) Construction and Aftercare ........................................................................................................... 390
(i) Equipment ................................................................................................................................................. 391
(ii) Rates of application of material ................................................................................................................ 391
DIVISION 6400: ASPHALT ROAD BASE AND SURFACINGS ....................................................................... 398
6401 Scope ........................................................................................................................................ 398
6402 Materials ................................................................................................................................... 398
(a) General .......................................................................................................................................... 398
(b) Bituminous binders ....................................................................................................................... 398
(i) Penetration Grade Bitumen (Based on SANS 4001-BT1) ........................................................................ 398
(ii) Modified Binders (based on TG1, 3rd edition, 2014 from SABITA) ........................................................ 399
(iii) Requirement for Rubber Crumb for modified bitumens (based on the prevailing version of TG1 from
SABITA) ............................................................................................................................................................. 400
(c) Aggregate Properties ..................................................................................................................... 400
6403 Mix Design ................................................................................................................................ 403
(a) Mix Proportions ............................................................................................................................ 405
(i) Continuously graded Asphalt Concrete (AC) wearing courses ................................................................. 405
(ii) Continuously-graded AC binder courses and road bases .......................................................................... 406
(iii) Dense Bitumen Macadam (DBM) ............................................................................................................ 406
(iv) Gap-graded Mixes .................................................................................................................................... 407
(v) Stone Mastic Asphalt (SMA) .................................................................................................................... 408
(vi) Open-graded mixes ................................................................................................................................... 409
(vii) Rolled-in chippings ........................................................................................................................ 410
(viii) Filler ............................................................................................................................................... 410
(b) Mix Design Specifications for Conventional Asphalts and Macadams ........................................ 411
(i) Mix design for continuously graded wearing courses............................................................................... 411
(ii) Mix design for traffic < 5 million ESA. .................................................................................................... 412
(iii) Mix design for traffic greater than 5 million ESA .................................................................................... 412

(iv) Other considerations for design of continuously graded mixes ................................................................ 413
(v) Mix design for severe sites ........................................................................................................................ 413
(vi) Grade of bitumen ...................................................................................................................................... 414
(vii) Mix design for Dense Bitumen Macadams .................................................................................... 414
(viii) Mix design for Gap-graded mixes .................................................................................................. 414
(ix) Mix design for open graded mixes ............................................................................................................ 414
(c) Mix Design Specifications for Recycled Asphalt ..........................................................................414
(i) Asphaltic materials for hot plant mix recycling - recovered asphaltic mixes............................................ 415
(ii) Bituminous binders ................................................................................................................................... 415
(iii) New Aggregate.......................................................................................................................................... 415
(iv) Combined Aggregate ................................................................................................................................ 415
(v) Storing material for recycling ................................................................................................................... 415
(vi) Hot in-situ surface recycling ..................................................................................................................... 416
(vii) Mixing plant. .................................................................................................................................. 416
(d) Fibres .............................................................................................................................................416
(e) Asphalt reinforcing ........................................................................................................................ 416
6404 Production of a Job (or Working) Mix ....................................................................................... 416
6405 Plant and Equipment................................................................................................................. 417
(a) General ..........................................................................................................................................417
(b) Mixing plant ..................................................................................................................................417
(i) Conventional binders ................................................................................................................................ 417
(ii) Non-homogeneous modified binders (bitumen-rubber) ............................................................................ 418
(iii) Homogeneous modified binder ................................................................................................................. 418
(iv) Recycled material...................................................................................................................................... 418
(c) Spreading equipment ..................................................................................................................... 418
(i) Paver ......................................................................................................................................................... 418
(ii) Chip spreader ............................................................................................................................................ 418
(d) Rollers ...........................................................................................................................................418
(i) General requirements ................................................................................................................................ 418
(ii) Non-homogeneous modified binder asphalt ............................................................................................. 419
(iii) Homogeneous modified binder asphalt ..................................................................................................... 419
(e) Binder distributors ......................................................................................................................... 419
(f) Trucks for transporting asphaltic mixes ........................................................................................ 419
(g) Mass-measuring device for asphalt mixes ..................................................................................... 419

6406 General Limitations and Requirements and the Storage of Mixed Material ............................. 419
(a) Weather conditions ........................................................................................................................ 419
(b) Moisture ........................................................................................................................................ 420
(c) Surface requirements..................................................................................................................... 420
(i) Correction of base layer (and sub-base in the case of asphaltic basecourse) ............................................ 420
(ii) Cleaning of surface ................................................................................................................................... 420
(iii) Tack coat ................................................................................................................................................... 420
(iv) Preparation for placing the overlays ......................................................................................................... 421
(v) Preparation where asphalt layers are to be widened or where surfacing over a section of the road width
requires replacement ............................................................................................................................................ 421
(d) Storage .......................................................................................................................................... 421
6407: Producing and Transporting the Mixture .................................................................................. 421
(a) Mixing and storage temperatures of binder and asphaltic mixes .................................................. 421
(b) Production of the mixture ............................................................................................................. 422
(i) Using batch plants..................................................................................................................................... 422
(ii) Using drum-type mixer plants .................................................................................................................. 422
(c) Transporting the mixture ............................................................................................................... 422
(d) Small quantities of asphalt ............................................................................................................ 422
(e) Recycled asphalt ........................................................................................................................... 422
6408 Spreading the Mixture .............................................................................................................. 423
(a) General .......................................................................................................................................... 423
(b) Overlays ........................................................................................................................................ 424
(c) Restricted areas ............................................................................................................................. 424
(d) Recycled asphaltic mixes .............................................................................................................. 424
6409 Joints ........................................................................................................................................ 424
6410 Pre-Coated Chippings for Asphalt Surfacing ............................................................................ 425
6411 Compaction............................................................................................................................... 425
(a) General .......................................................................................................................................... 425
6412 Laying Trial Sections ................................................................................................................ 427
(a) Construction tolerances ................................................................................................................. 428
(i) Level and grade ........................................................................................................................................ 428
(ii) Width ........................................................................................................................................................ 428
(iii) Thickness .................................................................................................................................................. 428
(iv) Cross section ............................................................................................................................................. 428

(v) Surface irregularity ................................................................................................................................... 429
(vi) Multiple-layer base ................................................................................................................................... 429
(b) Spread rate of rolled-in chippings .................................................................................................429
(c) Gradings ........................................................................................................................................429
(d) Binder content ............................................................................................................................... 430
(e) Voids ..............................................................................................................................................430
(f) Construction tolerances for overlays ............................................................................................. 430
6415 Quality of Materials and Workmanship ..................................................................................... 430
(a) Sampling .......................................................................................................................................430
(b) Coring of asphaltic layers ..............................................................................................................430
(c) Routine inspection and tests ..........................................................................................................431
DIVISION 6500: SURFACING OF BRIDGE DECKS ..................................................................................... 437
6501 Scope ........................................................................................................................................ 437
6502 Materials.................................................................................................................................... 437
6503 Preparation of Surface .............................................................................................................. 437
6504 Type and Thickness of Surfacing .............................................................................................. 437
6505 Construction .............................................................................................................................. 437
6506 Surface Tolerances ................................................................................................................... 437
DIVISION 6600: TREATMENT OF CERTAIN DEFECTS IN EXISTING BITUMINOUS SURFACING........................ 439
6601 Scope ........................................................................................................................................ 439
6602 Materials.................................................................................................................................... 439
(a) Bituminous binders ....................................................................................................................... 439
(i) Primer for sealing cracks ........................................................................................................................... 439
(ii) Binders for crack treatment ....................................................................................................................... 439
(iii) Fog spray................................................................................................................................................... 440
(iv) Tack coat for texturing .............................................................................................................................. 440
(v) Slurry-seal ................................................................................................................................................. 440
(vi) Screed........................................................................................................................................................ 440
(vii) Binder in asphalt for patching ........................................................................................................ 440
(b) Herbicides .....................................................................................................................................440
6603 Plant and Equipment................................................................................................................. 440

(a) Planing machine ............................................................................................................................ 440
(b) Equipment for crack-sealing ......................................................................................................... 440
(c) Other equipment ............................................................................................................................ 440
6604 Construction.............................................................................................................................. 441
(a) Treatment with diluted bituminous emulsion (fog spray) ............................................................. 441
(b) Texturing ....................................................................................................................................... 441
(c) Slurry texture treatment ................................................................................................................ 441
(d) Screed............................................................................................................................................ 442
(i) Asphalt Concrete or Hot Mix Asphalt ...................................................................................................... 442
(ii) Coarse slurry ............................................................................................................................................. 442
(iii) Requirements for evenness ....................................................................................................................... 442
(e) Repairing edge breaks in surfacing ............................................................................................... 442
(f) Sealing cracks ............................................................................................................................... 443
(i) General ..................................................................................................................................................... 443
(ii) Preparation ................................................................................................................................................ 443
(iii) Cracks smaller than 3 mm ........................................................................................................................ 443
(iv) Cracks of 3 mm and wider ........................................................................................................................ 443
(v) Other sealants ........................................................................................................................................... 443
(vi) Restrictions ............................................................................................................................................... 443
(g) Pre-treatment of the road surface by means of planing ................................................................. 444
(i) Fog spraying of planed surfaces ............................................................................................................... 444
6605 Opening to Traffic ..................................................................................................................... 444
DIVISION 6700: BITUMINOUS ROAD-MIX SURFACING ............................................................................. 448
6701 Scope ........................................................................................................................................ 448
6702 Materials ................................................................................................................................... 448
(a) New Aggregate (Case 1) ............................................................................................................... 448
(b) Aggregate from the Existing Surface (Case 2).............................................................................. 448
(c) Bituminous Materials .................................................................................................................... 449
6703 Equipment................................................................................................................................. 449
6704 Construction.............................................................................................................................. 449
(a) Weather Limitations ...................................................................................................................... 449
(b) Preparation of Road base and New Aggregate (Case 1) ............................................................... 449
(c) Preparation of Road base and Salvaged Aggregate (Case 2) ........................................................ 450
(d) Windrowing and Sampling............................................................................................................ 450

(e) Additive .........................................................................................................................................450
(f) Mixing ...........................................................................................................................................450
(g) Laying, Compacting and Finishing ............................................................................................... 451
(i) Spreading and blade finishing. .................................................................................................................. 451
(ii) Rolling finished surface. ........................................................................................................................... 451
(iii) Shaping edges ........................................................................................................................................... 451
(h) Improving Unsatisfactory Areas ....................................................................................................451
6705 Tolerances ................................................................................................................................. 451
(a) Thickness Requirements ...............................................................................................................451
(b) Seal Coat .......................................................................................................................................452
(c) Surface Requirements ...................................................................................................................452
(d) Stockpiling ....................................................................................................................................452

LIST OF TABLES
Table 6102/1: Prime Selection matrix .................................................................................................. 344
Table 6106/1: Recommended storage and application temperatures................................................. 345
Table 6206/1: Recommended Storage and Application Temperatures ............................................... 349
Table 6303/1: Specifications for Penetration Grade Bitumens ............................................................ 352
Table 6303/2: Specifications for MC 3000 ........................................................................................... 353
Table 6303/3: Bitumen Content Limits for Emulsion Grades .............................................................. 353
Table 6303/4: Classification for Modified Binders for Surface Seals................................................... 354
Table 6303/5: Specification for Hot Applied Polymer Modified Binders for Surface Seals .................. 354
Table 6303/6: Specification for Polymer Modified Emulsions for Surface Seals ................................. 354
Table 6303/7: Specifications for Bitumen Rubber for Surface Seals .................................................. 355
Table 6303/8: Specifications for Rubber Crumbs for Modified Binders ............................................... 355
Table 6303/9: Specified sizes for given nominal sizes ........................................................................ 356
Table 6303/10: Grading limits, specified size and maximum flakiness index for surface seal aggregates
.................................................................................................................................................... 356
Table 6303/11: Grading limits, specified size and maximum flakiness index for surface dressing
aggregates for lightly trafficked roads (<100 AADT) ................................................................... 356
Table 6303/12: 10% FACT Limits for Surface Sealing Aggregates ..................................................... 357
Table 6303/13: Minimum Polished Stone Values (PSV) for Surfacings .............................................. 358
Table 6303/14: Sands for Surface Treatments .................................................................................... 360
Table 6303/15: Aggregates Gradings for Slurry Seals ........................................................................ 360
Table 6303/16: Aggregates for Rapid Setting Slurry Seals ................................................................. 361
Table 6305/1: Minimum Road Surface Temperatures for Spraying Binder for Surface Seals ............ 367
Table 6305/2: Addition of Kerosene .................................................................................................... 368
Table 6305/3: Storage and spraying temperature for bituminous binders for Surface Seals ............. 369
Table 6305/4: Temperature/Time Limits for Modified Bituminous Binders for Surface Seals ............. 369
Table 6314/1: Minimum testing frequencies for Surface Seals ........................................................... 379
Table 6315/1: Chippings - Average Least Dimension (ALD) ............................................................... 380
Table 6315/2: Nominal Application Rates for Chippings and Conventional Binders (Tender purposes
only) ............................................................................................................................................ 380
Table 6316/1: Nominal Rates of Application for the First Layer (Tender purposes only) .................... 381
Table 6316/2: Nominal Rates of Application for the Second Layer (Tender purposes only) ............... 381
Table 6317/1: Nominal Rates of Application for the First Layer (Tender purposes only) .................... 383
Table 6317/2: Nominal Rates of Application for the Second and Third Layers (Tender purposes only)
.................................................................................................................................................... 383
Table 6318/1: Nominal Application Rates for Chippings and Conventional Binders (Tender purposes
only) ............................................................................................................................................ 384
Table 6320/1: Grading for Otta Seals .................................................................................................. 389
Table 6320/2: Aggregate Strength for Otta Seals, General Requirements ......................................... 390
Table 6320/3: Aggregate Strength for Otta Seals, AADT less than 100 .............................................. 390
Table 6320/4: Alternative Gradings for Graded Seals ......................................................................... 390
Table 6402/1: Specifications for Penetration Grade Bitumens ............................................................ 399
Table 6402/2: Classification for Modified Binders for Hot Mix Asphalts .............................................. 399
Table 6402/3: Specification for Polymer Modified Binders for Hot Mix Asphalt ................................... 399
Table 6402/4: Specifications for Bitumen Rubber for Asphalt ............................................................. 400
Table 6402/5: Properties for Asphalt Aggregates ................................................................................ 402
Table 6402/6: Enhanced Specifications for Rolled-in Chippings, Open-Graded Surfacings and Stone
Mastic Surfacings ........................................................................................................................ 403
Table 6403/1: Tolerances for the Manufacture of Asphalt Concrete .................................................... 404
Table 6403/2: Deviation from approved target grading ....................................................................... 404
Table 6403/3: Particle Size Distributions for AC Wearing Courses (Asphalt Institute, 1994) .............. 405
Table 6403/4: Particle Size Distributions for AC Bases and Binder Courses (Asphalt Institute, 1994)406
Table 6403/5: Particle Size Distributions for DBM Wearing Courses .................................................. 406
Table 6403/6: Particle Size Distributions for DBM Binder Course and Base Layers .......................... 407
Table 6403/7: Particle size distribution for Gap-graded mixes ............................................................ 408
Table 6403/8: Particle size distribution for Stone Mastic Asphalt surfacings ....................................... 409
Table 6403/9: Particle size distribution for open-graded surfacings .................................................... 410
Table 6403/10: Particle size distribution for rolled-in chippings ........................................................... 410
Table 6403/11: Critical Values of VIM (after Secondary Compaction) ................................................. 411
Table 6403/12: Minimum VMA Specified for AC Mixes ....................................................................... 411
Table 6403/13: AC Wearing |Course Specifications for up to 5 million esa......................................... 412
Table 6403/14: AC wearing course specification for more than 5 million esa ..................................... 413
Table 6403/15: Marshall criteria for Dense Bitumen Macadams ......................................................... 414
Table 6407/1 Temperature requirements for asphaltic mixes with conventional binders ........... 421
Table 6407/2: Temperature requirements for asphaltic mixes with modified binders .......................... 421
Table 6414/1: Deviation from Longitudinal Grade ............................................................................... 428
Table 6414/2: Thickness Tolerances.................................................................................................... 428
Table 6414/3: Surface Irregularity Limits ............................................................................................. 429
Table 6414/4: Deviation from approved target grading ....................................................................... 429
Table 6602/1: Property requirements for modified crack sealants ...................................................... 439
Table 6702/1: Grading Requirements for Road Mix Bituminous Surface Courses ............................. 448

Division 6100 – Bituminous Prime Coat
6101 Scope
This Division covers the application of a suitable bituminous binder to a non-bituminous granular
pavement layer or chemically stabilised layers as a preliminary treatment prior to the application of a
bituminous base or surfacing. The application is called the prime coat with a function of penetrating the
layer to which it is applied while leaving a small residual amount of binder on the surface to:
 Assist in promoting adhesion between the granular layer and the bituminous base or
surfacing;
 Inhibit water ingress into the prepared base while not hampering the migration of water in the
vapour phase out of the base;
 Limit absorption of binder from the next application of bituminous material into the base;
 Bind the finer particles in the upper portion of the granular material to accommodate light
construction traffic for a short period until the new surfacing can be placed if approved by the
Engineer.
6102 Materials
(a) Priming material

The priming material shall be one of the following as specified or as directed by the Engineer:
 MC 30 cutback bitumen complying with AASHTO M 82 or SANS 4001-BT2;

 Invert bitumen emulsion complying with SANS 4001-BT5 (previously SABS 1260). Invert
emulsion is distinct from normal bitumen-dispersed-in-water emulsion in that the water is
dispersed in the binder phase. These types of emulsions are manufactured with cutback
bitumens and shall have water contents of less than 20%.
For health and safety reasons, no tar-based primes shall be permitted under any circumstances.
If problems are encountered with MC 30 not penetrating dense crushed stone bases, chemically
stabilised bases or natural gravel bases with relatively high clay content, on approval of the Engineer,
the viscosity of the MC 30 shall be reduced by adding 10 – 15% of an approved cutter (eg kerosene
illuminating paraffin); and/or the prime application rate shall be lowered. The addition of cutter shall
take place in a controlled environment at the binder manufacturers blending plant for safety reasons
and to ensure a homogeneous mix. Alternatively, MC 10 complying with SANS 4001-BT2 shall be
used on approval of the Engineer.
In the case of inverted emulsions, the cutter and/or water content can be increased. However, the
maximum water content limit of 20% of the total volume of inverted emulsion shall not be exceeded.
Table 6102/1 provides the main factors that influence the selection of the type of primes to be used
depending on the absorptive properties of the base and the prevailing weather conditions.
(b) Mineral Aggregate for Blinding

The Aggregate used for blinding the primed surface shall consist of crushed rock or river sand, with
100% passing the 6.7 mm sieve and not more than 10% passing the 2.36 mm sieve. The Aggregate
shall be clean, hard and free from excessive dust. It shall contain no clay, loam, or other deleterious
matter.

Table 6102/1: Prime Selection matrix
Inverted
Type of base MC 30
Emulsion
Graded natural gravel eg weathered GB2/GB3 1 1
Crushed stone eg unweathered GB1 2* 1
Lime or cement stabilised 1 1
Bituminous stabilised - 2
Calcrete 1 1
Containing soluble salts - -
High moisture content - -
Low moisture content 1 1
High degree of densification - 2
Low degree of densification 1 1
High porosity 2 2
Low porosity - 2
Plasticity index >7 - -
Plastic Index <7 1 1
Open graded 2 2
High Humidity 1 -
Wet - 2
Road temperature >25ºC 1 2
Road temperature <25ºC 2 1
1 = Primary recommendation; 2 = Secondary recommendation; - = Unsuitable
* Lower viscosity by cutting back with illuminating paraffin or kerosene
6103 Safety
As specified in Clause 6302.
6104 Equipment
The following equipment as specified in Clause 6304 shall be available and in good working order:
 Bitumen Binder Distributor;

 Water sprinkler;
 Mechanical sweepers;
 Air blowers;
 Other equipment such as hand brooms, reinforced paper for joints, string, nails, and all other
ancillary equipment required to carry out the operation efficiently and neatly.
6105 Weather and Other Limitations

No prime shall be applied under the following adverse conditions:
 During foggy or wet conditions;

 When rain is imminent;
 When wind is sufficiently strong to cause uneven spraying;
 When the surface of the layer is wet, i.e. more than damp;
 When at any position the moisture content of the top 25 mm of the layer to be primed is
greater than 70% of the optimum moisture content of the material in the layer;
 When the temperature of the surface immediately prior to commencing the application of the
prime is below or, in the opinion of the Engineer, likely to fall below 10ºC;
 After sunset.

The Engineer's decision on whether or not to apply the prime coat under specific weather conditions
shall be final.
Bases containing soluble salts shall be primed immediately after completion of the base and shall be
surfaced within 24 hours with hot bitumen or modified bitumen. The base shall not be dampened
before priming as this could cause the dissolved salts to migrate to the surface and recrystallize during
the curing of the prime.
6106 Storage of Prime Coat Material

All prime materials stored in a heated condition shall be stored in a container with a properly
functioning circulation system and a securely fitting lid. Unless the prime material is intended for
immediate use, no heat shall be applied to material delivered above storage temperature until the
temperature is below those specified in Table 6106/1. To prevent undue evaporation of volatiles, which
will result in hardening of the material, prime shall not be heated to a temperature greater than 10°C
above the range specified. When prime has to be heated from the cold state, it shall be heated slowly
to avoid overheating that part of the prime that is close to the source of heat. Heated storage tanks
shall be fitted with suitable dial-type calibrated temperature indicators to show both the temperature in
the tank close to the source of heat and, as accurately as possible, the maximum temperature of the
binder in the tank.
Table 6106/1: Recommended storage and application temperatures

* Maximum storage temperature
º Spraying temperature
Type of prime ( C) º *
range ( C)
Up to 24 hrs More than 24 hrs
MC-30 Cutback 50 30 45 - 60
Invert bitumen emulsion 60 Air 50 - 70
* Temperatures may be above the flash point of some materials. Care must be taken to prevent fire and explosion.
6107 Preparation of the Layer to be Primed

Before any prime material is sprayed, the layer to be primed shall be checked for compliance with the
surface and other requirements specified. All superficial laitance or “biscuit” layers of fine material and
animal droppings shall be removed and may require the use of water, brooms and spades. Particular
attention shall be paid to areas where traffic diversions have traversed the layer to be primed. Any
sections not complying with the construction tolerances for completed base material specified in
Clause 5211 shall be corrected at the Contractor’s cost.
Not more than 24 hours before spraying, the layer to be primed shall be broomed and cleaned of all
loose or deleterious material by means of a rotary broom and hand brooms. Surfaces that are open
textured may require the use of compressed air. Brooming and cleaning shall be done carefully so as
to avoid any damage to the layer.
A light spray of water, sufficient to dampen the surface, shall be applied uniformly to the layer
immediately before the application of the prime. If excess water is over applied, the layer shall be
allowed to dry until a uniform damp surface is obtained.
If dust has been deposited on the surface to be primed, for whatever reason; between the time of
brooming and the time considered for application, the surface shall be broomed and cleaned again to
the satisfaction of the Engineer.

6108 Application of the Prime Coat

The application rates selected shall render a net residual binder of 0.35 kg/m². This equates to a spray
rate of 0.7 l/m² for MC 30 and 0.95 l/m² for inverted bitumen emulsion. The following adjustments to
the net residual binder shall be made on approval by the Engineer:
 If the base is coarse or open textured, increase the application rate by a maximum of 20%;
 If the base is dense and fine decrease the application rate by a maximum of 20%.
The Engineer may direct that trial applications be conducted through the “paint” test to ensure the
correct application. This is best achieved by marking out areas of 1m² and applying the candidate
prime with a brush at different application rates to determine the ideal application rate.
Recommended spraying temperatures are given in Table 6106/1. The spraying of the prime should not
commence if the surface temperature of the layer to be sprayed does not exceed 10ºC and rising.
Twine-reinforced paper or other suitable approved material shall be used at all joints at the beginning
and end of all sprays in order to obtain a neat start and cut-off line.
Wherever feasible, the prime shall be applied in one or more lanes evenly over the full width of the
road and allowed to penetrate and cure until traffic can pass over the surface without the wheels
picking up the prime. All traffic shall be kept off the surface until this condition is obtained.
Unless otherwise shown on the Drawings or directed by the Engineer, the total width of primed surface
shall be 150 mm wider on each side than the specified width of the final surfacing and the edges of the
prime shall be parallel to the centreline of the road.
Where it is not feasible for traffic to use diversions, the prime shall be applied and allowed to penetrate
for as long as is practicable before a blinding layer of mineral aggregate is applied at a rate of
3 2
0.0035 m /m . Care shall be exercised in this operation to avoid the mineral aggregate being applied
too soon after spraying the prime. Where practicable two to four hours shall elapse as directed by the
Engineer. Any "caking" of aggregate, which may take place and cause problems during the surfacing
process; and all loose aggregate, shall be removed before the final surfacing is commenced.
If prime is applied in more than one lane, allowance shall be made for overlapping the lanes by
150 mm.
Care shall be taken to protect any kerbing, guardrails, channelling, and gutters from the prime by
covering with a suitable protective material when spraying. The Contractor shall, at his own cost,
replace all soiled items that cannot be properly cleaned. Painting the soiled surfaces will not be
accepted as a suitable remedial measure.
After the prime has penetrated sufficiently, surplus prime shall be covered with damp crusher sand,
which shall be worked into it by means of hand brooms in order to absorb the surplus prime. As soon
as it is saturated with prime, the crusher sand shall be swept off the primed surface. The process shall
be repeated until no surplus prime remains on the primed surface.
For a given prime, the drying time will depend on the porosity of the base and the prevailing weather
conditions. The prime shall be allowed to dry to the satisfaction of the Engineer before opening to
traffic or proceeding with the construction of the next layer.
6109 Maintenance and Opening to Traffic

As far as practicable, traffic will be kept away from the primed surface and redirected to diversions.
Where this is not feasible and a blinding layer has been applied to the primed surface as per Clause
6108, the Contractor shall maintain the blinding layer and the primed surface during the period when
the surface is opened to traffic, and shall repair all damage caused to the blinding layer or the primed
surface by such traffic, as directed by the Engineer, at no additional payment to the Contractor.
6110 Tolerances
2
The actual spray rates shall not deviate by more than 0.05 litre/m from the required spray rate as
specified, or ordered by the Engineer. No payment shall be made for any material sprayed in excess of
2
0.05 litre/m more than the required spray rate.
6111 Testing
The Contractor shall give the Engineer at least 24-hours notice of his intention to spray prime material
so that the application process can be inspected and the Engineer can verify the actual spray rates.
The Contractor shall only spray when the Engineer or his representative is present.

Item 61.01 Prime coat:

(a) MC-30 cutback bitumen...............................................................................................litre (ℓ)
(c) Invert bitumen emulsion ..............................................................................................litre (ℓ)
The unit of measurement shall be the litre of prime measured at spraying temperature and sprayed as
required.
The tendered rate shall include full compensation for supplying the prime material, cleaning and
watering the layer to be primed, applying the priming material and maintaining the primed surface as
specified.
2
Item 61.02 Aggregate for blinding ................................................................. square metre (m )
The unit of measurement shall be the square metre of prime coat blinded with aggregate on
instructions from the Engineer.
The tendered rate shall include full compensation for procuring, furnishing, transporting and applying
the aggregate for blinding where directed by the Engineer; for the maintenance of the blinding layer as
specified; and for the removal of the blinding layer to the approval of the Engineer prior to surfacing.

Division 6200 – Tack Coat
6201 Scope
This Division covers the specification of materials for, and the application of, bituminous tack coats that
are applied to a primed surface or existing bituminous surface to promote adhesion between the
existing bituminous surface and the new asphalt pavement layer.
6202 Materials
(a) Tack coat material

The material used for tack coats shall be following as specified or as directed by the Engineer:
 Stable Grade 30% bitumen emulsion complying with AASHTO M-140 or M-208; or SANS
4001-BT3 and -BT4 (previously SANS 309 and 548).
(b) Water for the Production of Bitumen Emulsion

Water used for the production of bitumen emulsion shall comply with the requirements of water quality
type A in accordance with sub-clause 1209 (a).
6203 Equipment
The following equipment as specified in Clause 6304 shall be available and in good working order:
 Bitumen Binder Distributor;

 Mechanical sweepers;
 Air blowers;
 Other equipment such as hand brooms, reinforced paper for joints, string, nails, and all other
ancillary equipment required to carry out the operation efficiently and neatly.
6204 Weather and Other Limitations

No tack coat shall be applied under the following adverse conditions:
 During foggy or wet conditions;

 When rain is imminent;
 When wind is sufficiently strong to cause uneven spraying;
 When the surface of the layer is wet or damp;
 When the temperature of the surface of the layer immediately prior to commencing the
application of the tack coat is below 20ºC (10ºC for emulsions);
 When the air temperature immediately prior to commencing the application of the tack coat is
below or, in the opinion of the Engineer, likely to fall below 10ºC;
 After sunset.
The Engineer's decision on whether or not to apply the tack coat under specific weather conditions
shall be final.

6205 Storage of Tack Coat Material

All tack coat materials stored in a heated condition shall be stored in a container with a properly
functioning circulation system and a securely fitting lid. Unless the tack coat material is intended for
immediate use, no heat shall be applied to material delivered above storage temperature until the
temperature is below those specified in Table 6206/1. The tack coat material shall not be heated to a
temperature greater than 10ºC above the range specified. When tack coat has to be heated from the
cold state, it shall be heated slowly to avoid overheating that part of the tack coat that is close to the
source of heat. Heated storage tanks shall be fitted with suitable calibrated temperature indicators to
show both the temperature in the tank close to the source of heat and, as accurately as possible, the
maximum temperature of the material in the tank.
Tack coat material supplied in barrels or drums shall be decanted into heated storage tanks as
indicated herein.
Table 6206/1: Recommended Storage and Application Temperatures

*
Maximum storage temperature º *
Spraying temperature ( C)
Type of tack coat (º C)
< 24 hrs > 24 hrs Range Recommended
Bitumen emulsion 60 Ambient 50 - 70 60
* Temperatures may be above the flash point of some materials. Care must be taken to prevent fire and explosion.
6206 Surface Preparation

Prior to the application of the tack coat, the surface to be treated shall be checked for compliance with
the surface and other requirements specified. Not more than four (4) hours before application of the
tack coat, the surface shall be cleaned of loose material, dust, animal droppings and other deleterious
materials, which may require the use of water, approved mechanical brooms or blowers, hand brooms
and spades. Particular attention shall be paid to areas where traffic diversions have traversed the layer
to be treated. The surface of any section, which in the opinion of the Engineer is unsatisfactory for the
application of a tack coat, shall be corrected at the Contractor’s cost.
Surfaces that are open textured may require the use of compressed air. Brooming and cleaning shall
be done carefully so as to avoid any damage to the layer.
If dust has been deposited, for whatever reason, on the surface to be treated between the time it has
been broomed and the time considered for application, it shall be broomed and cleaned again to the
The surface shall be dry. No traffic shall be permitted on the surface to be treated after it has been
prepared to receive the bituminous material.
6207 Application of the Tack Coat

The rate of application shall be as directed by the Engineer. The Engineer may direct that trial
applications be conducted on short test sections to determine the optimum application rate for the
various layer materials to which the tack coat shall be applied. In general, for a stable grade emulsion
2
diluted to have a 30% bitumen content, the rate of application of tack coat shall be 0.2 to 0.6 litre/m
depending on the surface to be treated with tack coat; or as directed by the Engineer. Typical spray
rates are:
 New Hot Mix Asphalt – 0.25 litres/m²;

 Oxidised Hot Mix Asphalt – 0.4 litres/m²;
 Milled asphaltic material – 0.55 litres/m²;
 Milled cementitious material – 0.55 litres/m²;
 Concrete pavements – 0.4 litres/m².
The application of bituminous material shall not exceed the required amount. Any excess, which is
applied, shall be removed by the application of blotting material approved by the Engineer.
Recommended spraying temperatures are given in Table 6206/1.
Twine-reinforced paper or other suitable approved material shall be used at all joints at the beginning
and end of all sprays in order to obtain a neat start and cut-off lines.
Unless otherwise shown on the Drawings or directed by the Engineer, the total width of treated surface
shall be 100 mm wider on each side than the specified width of the final surfacing and the edges of the
tack coat shall be parallel to the centreline of the road.
If tack coat is applied in more than one lane, allowance shall be made for overlapping the lanes by
150 mm.
Care shall be taken to protect any kerbing, guardrails, channelling, and gutters from the tack coat by
covering with a suitable protective material when spraying. The Contractor shall, at his own cost,
replace all soiled items that cannot be properly cleaned. Painting the soiled surfaces will not be
accepted as a suitable remedial measure.
The tack coat shall not be applied more than 24 hrs before the paving is carried out.
6208 Traffic
Except for vehicles transporting materials for the overlying layer, no traffic shall be permitted on the
surface to be treated after it has been prepared to receive the bituminous material.
6209 Tolerances
The actual spray rates shall not deviate from the required spray rate as specified or ordered by the
2
Engineer by more than 0.05 litre/m .
6210 Testing
The Contractor shall give the Engineer at least 24-hours notice of his intention to spray tack coat
material so that the application process can be inspected and the Engineer can verify the actual spray
rates. The Contractor shall only spray when the Engineer or his representative is present.

Item 62.01 Tack coat

(a) Stable-grade bitumen emulsion (30%) ....................................................................... litre (ℓ)
The unit of measurement shall be the litre of bituminous material measured at spraying temperature
and sprayed as required.
The tendered rate shall include full compensation for supplying the tack coat material, cleaning the
surface to receive the tack coat and applying the tack coat material as specified.

Division 6300: Surface Seals
6301 Scope
This Division covers the general requirements for health and safety in the use of bituminous
products; materials used for surface seals; construction equipment, and construction methods; and
requirements for all surface treatments or seals specified in these Specifications.
For the purpose of these Specifications, surface seals refer to the wearing surface of a road using
a thin layer or layers of bitumen and mineral aggregate to improve the functional aspects of a
surfaced road in terms of waterproofing the underlying pavement layers from water ingress;
improved riding quality; and improved skid resistance. Surface treatments covered in this Division
provide no structural strength component to the pavement.
6302 Health and Safety

In addition to the general requirements for Health and Safety set out in Clauses 1215 and 1613 of
these specifications, the Contractor shall take all necessary precautions for the safe handling and
application of bituminous binders, especially when the binder is cut back with flammable materials.
Attention is drawn to the risk of fire and toxic fumes, which may cause extensive damage to the
equipment and injury to the equipment operators. Suitable fire-fighting equipment for dealing with
bitumen fires shall be available at the site of the bitumen works, together with suitable first-aid
equipment for dealing with bitumen burns.
Precautions are partly dependent on the design of equipment but suitable training and rehearsal of
the crews handling bituminous binders is essential. Suitable fire extinguishers shall be provided and
shall be readily accessible during all operations involving the handling, transportation, storage or
heating of bituminous binders.
Crewmen shall wear heat-resistant gauntlet gloves. Facemasks shall be worn when a spray lance
is used because of possible rupture of the armoured hose.
Bitumen distributors and storage tanks shall not be flushed by means of splash filling with
petroleum products. The flushing hose shall be inserted in the bottom of the tank.
6303 Materials
(a) Bituminous Binders

The type and grade of bituminous binder to be used shall be that specified under the appropriate
Division and Clauses of these Specifications for each type of bituminous surface treatment, or in
the Particular Specifications, or as ordered by the Engineer.
Duplicate delivery slips shall accompany each load of bituminous material and shall contain the
name of the producer and the supplier, the type and grade of material, the loading temperature of
the material, and the lot number and date of approval of the material from which delivery is made.
When considered necessary by the Engineer and at his sole discretion, a time limit may be
imposed between the date of approval and the date of delivery, or between the date of approval
and the date of use in the Works.
The Contractor shall provide to the Engineer certificates issued by all suppliers of bituminous
binders to the effect that the binders delivered to the Site comply with the test requirements
specified herein.

The Engineer shall have the authority to order the Contractor to have the bituminous binders tested
by an approved laboratory for compliance with all or any of the requirements specified and the
results of such tests shall be submitted directly by the testing laboratory to the Engineer with copies
if requested to the Contractor.
(i) Selection of Bituminous Binders

The selection of bituminous binders is dictated by several factors. These include the material that
has to be bound together; prevailing environmental conditions of climate and traffic both in service
and during construction; geographic location; topography; traffic loading; costs and budgets;
specified construction methods; and various other specific requirements imposed by the Employer.
Each project is unique and requires extensive experience in the selection of a suitable bituminous
binder specified in the relevant clauses of these specifications.
(ii) Penetration Grade Bitumen (Based on SANS 4001-BT1)

The specifications for penetration grade bitumens for surface seals are shown in Table 6303/1.
Table 6303/1: Specifications for Penetration Grade Bitumens

Penetration Grade
Property 70/100 150/200 Test Method
Requirement Limits
Penetration @ 25ºC (100g/5s) , 0.1mm 70 – 100 150 – 200 EN 1426
Softening Point, ºC 42 – 51 36 – 43 ASTM D361
Minimum viscosity @ 60ºC, mPa.s 75 30 ASTM D44022
Viscosity @ 135ºC, mPa.s 150 – 400 120 – 300 ASTM D44022
Flash point, ºC, min 230 220 ASTM D92
Mass Change, % max 0.3 0.3 ASTM D2872
Performance Viscosity @ 60ºC, % of ASTM D44022
300 300
when original max
subjected to Softening Point, ºC min 44 37 ASTM D361
rolling thin film Increase in Softening Point,
7 7 ASTM D361
oven test, ºC max
ASTM D2872 Retained Penetration, % of
50 50 EN 1426
original min
3
Spot test, % xylene max 30 30 AASHTO T102
1
Using shouldered rings in the test
2
Recommended apparatus is the RV viscometer, using SC4dles with the Thermosel system
3
Actual values to be reported in 5-unit intervals
(iii) Cutback Bitumen (Based on SANS 4001-BT2, previously SANS 308)

Unless specified in the Particular Specifications or instructed by the Engineer, cutback bitumen
used for surface seals shall be MC 3000 and shall meet the requirements of Table 6303/2 and any
other requirements of SANS 4001-BT2.

Table 6303/2: Specifications for MC 3000
Requirement
Property Limits Test Method
Min Max
Kinematic viscosity @ 60°C, cSt 3 000 6 000 ASTM D2170
Dynamic viscosity @ 60°C mPa.s 3 000 7 000 ASTM D4402
Flash point (°C) 38 - ASTM D93
Water (% by mass or volume) - 0.2 ASTM D95
Distillation at 101.325 kPa absolute Distillation test to 190°C Value to be reported
Distillation test to 225°C 0 25
ASTM D402
Distillate % (by volume) of total Distillation test to 260°C 0 40
distillate to 360 Distillation test to 316°C 35 80
Residue from distillation to 360°C, % (by volume) (by difference) 80 - ASTM D402
Viscosity @ 60°C on residue from distillation, mPa.s 30 - ASTM D4402
In conditions of lower air and surface temperatures for sealing operations, MC 800 shall be used on
instruction of the Engineer, or as required in the particular specifications. Should MC 800 not be
readily available from suppliers, the contractor, on instruction by the Engineer, shall be allowed to
cut back MC 3000 with an approved cutter such as kerosene or power paraffin. Alternatively, MC
3000 shall be blended with MC 30 to achieve the required viscosity. Any cutting back and blending
operations undertaken by the contractor shall observe all necessary health and safety precautions,
especially related to the flammability of the cutter.
(iv) Bitumen Emulsions (also called emulsified asphalts)

Bitumen emulsions shall meet the following specifications for anionic and cationic emulsions used
in the Works:
 Anionic bitumen emulsions to AASHTO M 140 (or SANS 4001-BT3 previously SANS 309)
 Cationic bitumen emulsions to AASHTO M 208 (or SANS 4001-BT4 previously SANS 548)
The binder contents for the various grades of emulsion shall be as shown in Table 6303/3.
Table 6303/3: Bitumen Content Limits for Emulsion Grades

Binder Content (% by mass)
Grade
Min Max
Anionic stable mix 60 62
Cationic stable mix 60 63
Anionic spray 60 60 62
Cationic spray 60 60 63
Cationic premix 60 60 63
Cationic premix 65 65 68
Spray-grade bitumen emulsions for surface seals shall have the following viscosity requirements:
 Anionic spray-grade emulsion (60 %): minimum 12 degrees Engler at 20ºC to method
ASTM D-1665.
 Cationic spray-grade emulsion (60, 65, 70 %): minimum 80 seconds Saybolt Furol at 50ºC
to method ASTM D244.
Water used for the production of bitumen emulsion shall comply with the requirements of water
quality type A of Clause 1209.
rd
(vii) Modified Binders (based on TG1, 3 edition, 2014 from SABITA)
Modified bituminous binders shall be divided into the following two broad compositional groups:

 Homogenous Binders;
 Non-homogenous Binders
The generic modified binders classified in Table 6303/4 are suitable for surface seals
Table 6303/4: Classification for Modified Binders for Surface Seals

Modified Binder Class Compositional Group Application
S-E1 Homogenous Surface Seals – Hot applied elastomer modified
S-E2 Homogenous Surface Seals – Hot applied elastomer modified
S-R1 Non-homogenous Surface Seals – Hot applied bitumen rubber
SC-E1 Homogenous Surface Seals – Emulsion elastomer modified
SC-E2 Homogenous Surface Seals – Emulsion elastomer modified
The properties of the modified binder classes shown in Table 6303/4 are specified in Tables
6303/5, 6303/6 and 6303/7.
Table 6303/5: Specification for Hot Applied Polymer Modified Binders for Surface Seals
Test method Class
Property Unit (as provided in TG 1 unless
indicated otherwise)
S-E1 S-E2
Before Ageing
1 2
Softening Point ºC MB-17 50 - 70 60 – 80
Elastic recovery @ 15ºC % MB-4 > 50 > 60
Dynamic Viscosity @ 165ºC Pa.s MB-18 ≤ 0.55 ≤ 0.60
Stability @ 160ºC ºC MB-6 ≤5 ≤5
Flash Point ºC ASTM D92 ≥ 230 ≥ 230
After Ageing with Rolling Thin Film Oven (RTFOT) to ASTM D2872
Mass Change % MB-3 ≤ 1.0 ≤ 1.0
1
The prescribed test method is based on not using stirrers although it has been reported that the use of stirrers has shown
no difference in test results. For refereeing purposes, no stirrer should be used.
2
The softening point values obtained for bitumen modified with SBS will tend to fluctuate over time and reheating.
Table 6303/6: Specification for Polymer Modified Emulsions for Surface Seals
Test method Class
(as provided in TG 1
Property Unit
unless indicated SC-E1 SC-E2
otherwise)
Binder content (m/m) % MB-22 65-68 70-73 65-68 70-73
Saybolt Furol viscosity @ 50ºC Sec MB-21 51-200 51-400 51-200 51-400
Residue on Sieving 710 µm ≤ 0.1 ≤ 0.1
g MB-23
(/100 ml) 150 µm ≤ 0.5 ≤ 0.5
Particle Charge MB-24 positive positive
Sedimentation after 60 rotations ºC SANS 4001-BT3 nil nil
Recovered binder residue to MB-20
Softening Point ºC MB-17 ≥ 48 ≥ 55
Elastic Recovery @ 15 ºC % MB-4 ≥ 50 ≥ 55

Table 6303/7: Specifications for Bitumen Rubber for Surface Seals
Test method Class

Property Unit
unless indicated S-R1
otherwise)
Softening Point ºC MB-17 55 – 65
Dynamic Viscosity @ 190ºC dPa.s MB-13 20 - 40
5 mins > 70
Compression
1 hour % MB-11 > 70
Recovery
24 hours > 40
Resilience @ 25 ºC % MB-10 13 - 35
Flow Mm MB-12 15 - 70
(viii)
(ix) Requirement for Rubber Crumb for modified bitumens (based on the prevailing version of
TG1 from SABITA)
Table 6303/8 shows the requirements for rubber crumbs for modifying bitumens.
Table 6303/8: Specifications for Rubber Crumbs for Modified Binders

Test method
Property Requirement (as provided in TG 1 unless
1.18 mm 100
Sieve Analysis
600 µm 40 - 70 MB-14
(% mass passing)
75 µm 0-5
Poly-Isoprene content (%m/m total hydrocarbon) > 25 Thermo-gravimetric Analysis
Fibre Length (mm) <6
Bulk Density (g/m³) 1.10 – 1.25 MB-16
(b) Aggregate Chippings for Surface Seals

The chippings used in surface seals should be:
 Strong, durable and sound;

 Single sized within a practical tolerance;
 Clean and free from dust;
 Cubical in shape, not rounded or flaky;
 Not susceptible to the polishing action of traffic.
It is usually impossible to obtain chippings that are perfectly cubical and meet all of the
requirements, therefore some compromise is necessary. Tests should be carried out to check the
following properties of the chippings:
 Grading
 Flakiness Index
 Aggregate Abrasion using the Los Angeles Abrasion (LAA) value
 Aggregate Crushing Value (ACV)
 Polished Stone Value (PSV)
 Bitumen Affinity, or the tendency of the aggregate to adhere to the bitumen.
(i) Grading and Flakiness

Grading and flakiness index limits are shown in Tables 6303/9, 6303/10 and 6303/11.

Table 6303/9: Specified sizes for given nominal sizes
Specified size (mm)

Retained on
Nominal Size (mm) Passing ISO
ISO test
test sieve
sieve
20 20 14
14 14 10
10 10 6.3
6 6.3 3.35
Table 6303/10: Grading limits, specified size and maximum flakiness index for surface seal
aggregates
Nominal size of aggregates (mm)

Grading limits*
20 14 10 6.3
28 mm 100 - - -
20 mm 85-100 100 - -
14 mm 0-35 85-100 100 -
10 mm 0-7 0-35 85-100 100
6.3 mm - 0-7 0-35 85-100
5.6 mm - - 0-10 -
3.35 mm - - - 0-35
2.36 mm 0-2 0-2 0-2 0-10
600 µm - - - 0-2
75 µm 0-1 0-1 0-1 0-1
Minimum percentage by mass retained on ISO test sieve
Specified size
65 65 65 65
Maximum flakiness index 25 25 25 -
*
In accordance with ISO 3310-1 specification for test sieves
Table 6303/11: Grading limits, specified size and maximum flakiness index for surface
dressing aggregates for lightly trafficked roads (<100 AADT)
Nominal size of aggregates (mm)

Grading limits*
20 14 10 6.3
28 mm 100 - - -
20 mm 85-100 100 - -
14 mm 0-40 85-100 100 -
10 mm 0-7 0-40 85-100 100
6.3 mm - 0-7 0-35 85-100
5.6 mm - - 0-10 -
3.35 mm - - - 0-35
2.36 mm 0-3 0-3 0-3 0-10
600 µm 0-2 0-2 0-2 0-2
75 µm - - - -
Minimum percentage by mass retained on ISO test sieve
Specified size
60 60 65 65
Maximum flakiness index 35 35 35 -
*
In accordance with ISO 3310-1 specification for test sieves
(ii) Strength, Abrasion and skid resistance

The required limits for the strength of surfacing aggregate determined by the 10% FACT (method
SANS 3001-AG10) are shown in Table 6303/12.

Table 6303/12: 10% FACT Limits for Surface Sealing Aggregates
Traffic (AADT) < 300 vpd 300 – 1000 vpd 1000 – 3000 vpd 3000 vpd
Ethiopian Road Class Up to DC 4 DC 5 DC 6 DC7 and above
Dry 10% FACT (kN) (min) 130 150 180 210
1
Wet 10% FACT (kN) (min) 100 115 135 160
E80s (20 years @ 10%
0.3 mil 1.0 mil 3.0 mil 10.0 mil
heavies, E80/h = 2,3% growth
1
This is a minimum wet strength value not a wet/dry ratio.
The following limits shall apply for aggregate abrasion and aggregate soundness:
 Los Angeles Abrasion value after 500 revolutions: ≤ 30 (AASHTO T-96);

 Sodium sulphate soundness value: ≤ 12 (AASHTO T-104).
The PSV is a measure of the resistance of the chippings to the polishing action of traffic and its
ability to provide suitable skid resistance. Minimum PSV for chippings are shown in Table 6303/13.
If enough time elapses before a reseal is applied to a double surface dressing, so that the first layer
of chippings becomes substantially exposed, the PSV specification should be applied to the
chippings in both the bottom and the top layer.

Table 6303/13: Minimum Polished Stone Values (PSV) for Surfacings
Traffic (cumulative vehicles/lane/day) at design life
1001 to 1250
1251 to 1500
1501 to 1750
1751 to 2000
2001 to 2250
2251 to 2500
2501 to 2750
2751 to 3250
751 to 1000
101 to 250
251 to 500
501 to 750
Over 3250
0 to 100
Site Definition
1. Motorway (main line).

Dual Carriageway (all purpose).Non-event sections.
55 57 60 65 68
Dual Carriageway (all purpose)
Minor junctions.
2. Single Carriageway non-event sections.

45 50 53 55 57 60 63 65 68
Single carriageway minor junctions.
3. Approaches to and across major junctions (all

limbs).
Gradient 5%-10%, longer than 50 m (dual downhill;
single uphill and downhill). 50 55 57 60 63 65 68 Over 70
Bend (not subject 64 kph or lower speed limit)
radius 100-250 m.
Roundabout.
4. Gradient ˃ 10% longer than 50 m (dual downhill;

single uphill and downhill).
55 60 63 65 68 Over 70
Bend (not subject to 64 kph or lower speed limit)
radius ˂ 100 m.
5 Approach to roundabout traffic signals, pedestrian 63 65 68 Over 70

crossing, railway level crossing, etc.

(iii) Bitumen Affinity and adhesion

The adhesion between the chippings and the bitumen can be assessed using the Modified Immersion
Tray Test (AASHTO T 182). Over 95 per cent of the bituminous material must be coated. This test
identifies whether the aggregate is likely to strip and the percentage of adhesion agent required for the
prevention of stripping.
If the chippings are dusty, the adhesion of the bitumen will be poor. The dust should be removed with
water. If water is not available within a reasonable haulage distance, or if the chippings become dusty
again when they are transported to site, the chippings should be pre-coated with a light spray of
creosote, diesel, kerosene or approved pre-coating fluid at ambient temperature.
(iv) Pre-coating of Aggregate

Where hydrophilic or other problematic aggregates are encountered, the Engineer may order that the
chippings be pre-coated, or that a fog spray be applied as specified in sub-clause 6306 (g).
The untreated aggregate shall be thoroughly wetted and allowed to drain off to a damp condition. An
approved pre-coating fluid (containing an approved wetting agent at a rate of 0.5 % by volume of the
pre-coating fluid) shall be applied at the rate of about 12 l/m³ of aggregate. The mixture of pre-coating
fluid and aggregate shall be suitably agitated, turned and mixed until the aggregate is uniformly coated
with the pre-coating fluid.
When there is a danger that the pre-coating fluid will be washed off by rain, the stockpiles shall be
covered with tarpaulins or similar protective coverings.
No pre-coating shall normally be applied where conventional and modified emulsion binders are to be
used unless specified or ordered by the Engineer. Pre-coated aggregates should be checked before
being used with emulsions to ensure that they will not influence the breaking of emulsion, particularly if
hard bitumen coated chippings are used.
The time between the pre-coating and the placing of the aggregate shall not exceed the time specified
in the Particular Specification or as agreed by the Engineer.
When aggregate is pre-coated with kerosene or diesel, all the volatiles in the contact area between the
chippings and binder must evaporate before allowing controlled traffic onto the road.
The amount of creosote, diesel or kerosene used will vary from approximately 0.5% by mass for
20mm chippings to 1.0% for 6mm chippings. Hard bitumen can also be used as a pre-coat, although
this requires a premix plant on site. Hard bitumen pre-coating cannot be used with most emulsions,
due to the adverse effects on the breaking of the emulsion.
Areas used for stockpiling pre-coated aggregates shall be so sited to minimise the deposition of dust
on the aggregates. Where necessary adjacent roads or diversions shall be watered or sealed. When
there is a danger that the pre-coating fluid will be washed off by rain the stockpiles shall be covered
with tarpaulins or similar protective coverings.
(v) Chipping Size and Application Rate

The nominal size of chippings used in surface dressing depends on the volume of traffic on the road
and the hardness of the road surface, as measured with the modified MEXE (Probe) Penetrometer
(see Pavement Design Manual Vol1, Flexible Pavements; and the Best Practice Manual for Thin
Bituminous Surfacings for more details) .
The size of the chippings and their rate of application will be determined by the Engineer based on the
design method described in the Best Practice Manual for Thin Bituminous Surfacings.
The Average Least Dimension (ALD) is required to determine the application rate of the bitumen.
An estimate of the spread rate of the chippings can be obtained from the equation:
2
Chipping application rate (kg/m ) = 1.364 x ALD
3
This equation assumes that the chippings have a loose density of 1.35 Mg/m .
(c) Sand for Surface Seals

The grading limits for sand and grit seals are shown in Table 6303/14.
Table 6303/14: Sands for Surface Treatments

Percentage passing by mass
Sieve Size (mm)
Sand seal Grit Seal
4.75 100
2.36 100 0 – 100
1.18 0 – 80 0 – 50
0.60 0 – 40 0 – 20
0.30 0 - 15 0 – 10
0.15 0-2 0–5
0.075 0-2
Sand Equivalent (%) ≥ 35
Note 1: Sand shall be Non Plastic
(d) Slurry Seals
(i) Aggregate Gradings for Slurry Seals

The aggregate for slurry seal shall be approved crusher sand obtained from a parent rock having a
Los Angeles Abrasion value not exceeding 40 or a mixture of crusher sand and approved clean natural
sand where the mixture contains not more than 25% of natural sand. The aggregate shall be clean,
tough, durable, angular in shape, and shall conform to the grading requirements of Table 6303/15.
Table 6303/15: Aggregates Gradings for Slurry Seals

Sieve size
Fine Slurry Coarse Slurry
(mm)
Fine Medium Coarse Type 1 Type 2
13.2 100
9.5 100 85 – 100
6.7 100 100 85 – 100 70 – 90
4.75 100 90 – 100 70 – 90 70 – 90 60 – 80
2.36 90 – 100 65 – 90 45 – 70 45 – 70 40 – 60
1.18 65 – 90 45 – 70 28 – 50 25 – 45 25 – 45
0.60 40 – 60 30 - 50 19 - 34 15 – 30 15 – 30
0.30 25 – 42 18 - 30 12 - 25 10 – 20 10 – 20
0.15 15 – 30 10 - 21 7 - 18 6 – 15 6 – 15
0.075 10 – 20 5 - 15 5 - 15 4 – 10 4 - 10
Sand equivalent ≥ 35
Bitumen content*
(% by mass of 10.0 – 16.0 7.5 – 13.5 6.5 – 12.0
dry aggregate)
* Bitumen content provided for tender purposes only.
The optimum mix design for the aggregate, filler, water and bitumen emulsion mixture should be
determined using ASTM D 3910.
Grading limits for rapid setting slurry seals are shown in Table 6303/16.

Table 6303/16: Aggregates for Rapid Setting Slurry Seals
Nominal maximum size (mm)

Sieve size 4.75 6.7 9.5 13.2
(mm) Overlays Rut Filling
13.2 100
9.5 100 80 – 100
6.7 100 66 – 100 60 – 84
4.75 100 70 – 100 57 – 75 50 – 70
3.35 80 – 100 50 – 75 48 – 85 44 – 62
2.36 64 – 80 46 – 60 42 – 56 38 – 57
1.18 40 – 55 32 – 47 28 – 43 28 – 43
0.60 27 – 38 20 – 34 18 – 33 18 – 33
0.30 14 – 24 10 – 22 10 – 20 10 – 20
0.15 9 – 18 7 – 16 7 – 14 7 – 14
0.075 5 - 15 5 - 10 5 - 10 5 - 10
Sand Equivalent (%) ≥ 35
Modified Emulsion (litres/m3) 200 190 160 150
Note: Bitumen content provided for tender purposes only.
(ii) Cement Filler for Slurry Seal

Portland cement shall comply with the requirements of AASHTO M 85 or equivalent grade in
accordance with ISO or Ethiopian Standards.
Road lime shall comply with the requirements of AASHTO M 216 (lime for stabilisation).
6304 Plant & Equipment
(a) General
All plant and equipment used on the Works shall be of adequate rated capacity and in good working
condition.
All plant and equipment that will be operated on the road during construction of the bituminous surface
treatment shall be free of any binder, fuel or oil leaks; and no refuelling or servicing of any equipment
will be allowed to take place while such equipment is on the road.
(b) Bitumen Distributor

The bitumen distributor shall comply with the following requirements:
 The distributor shall be so designed, equipped, maintained and operated that bituminous
material at a constant temperature may be applied uniformly on various widths of surface from
1.5 to 7.6 m at the specified rate of application;
 All dial gauges related to the control of the bitumen pump and spray equipment shall be at
least 100 mm in diameter and be accurate to ± five (5) per cent;
 The distributor shall be furnished with a sampling system complying with AASHTO T 40;
 The distributor shall be fitted with suitably calibrated temperature indicators to show both the
temperature at which the binder is being drawn off for application and, as accurately as
possible, the maximum temperature of the binder in the tank. Such indicators shall be capable
of measuring up to 200ºC and must be accurate to within ± 5ºC. They shall not be mounted on
the spray bar or any position where they will be subject to damage or excessive vibration.
They shall be mounted as low as possible near the heating line to limit any accidental
excessive heating of the binder.
 Constant pressure machines shall have pressure gauges on the spray bar and constant
volume machines shall have proper control of the speed of the engine operating the pump.

 All distributors shall be calibrated to ensure that the binder can be uniformly applied to the
surface of the road at the correct application rate and over the required width.
 Tests for uniformity of transverse distribution of binder shall be carried out according to the
Depot Spray Test (sub-sub-clause (i) of this sub-clause) before the commencement of binder
spraying works and at such other times as directed by the Engineer, at the Contractor’s cost.
Road tray tests shall be carried out, to check the longitudinal and transverse distribution of the
binder during operations. In the event of the results of the tests being unsatisfactory the
distributor shall be adjusted and retested to the satisfaction of the Engineer before the
spraying works may proceed;
 The distributor shall be free from binder or fuel leaks;
 The distributor shall be fitted with a rigid adjustable guide clearly visible from the driving seat
so that the distributor may be driven accurately to ensure regularity of edge lines and
overlaps;
 The distributor shall be fitted with an accurate means of measuring and indicating the road
speed of the vehicle at operational speeds. The road speed indicator shall be independent of
the normal vehicle speedometer. The indicator shall be so designed that the scale reading for
five (5) metres per minute measured on the periphery of a 100 mm diameter scale shall be not
less than 5mm. The indicator shall be accurate to within ± five (5) per cent and so placed that
it can be easily read by the driver of the distributor while causing the least distraction from the
efficient operation of the distributor;
 Pipes shall be provided with suitable couplings to ensure the safe transfer of binder to and
from the distributor for loading and unloading. In order to exclude suspended matter, which
might cause partial or complete blockage of the pumping or spraying equipment, a suitable
filter shall be provided through which all binder shall pass into the tank;
 The bitumen tank shall have an inspection manhole and a calibrated dipstick registering the
volume of the binder in the tank. Both the tank and the dipstick shall be stamped with a unique
serial number. A working platform or catwalk of mesh steel shall be provided adjacent to the
manhole to facilitate the reading of the dipstick. The dipstick shall be calibrated to an accuracy
of not less than one (1) per cent of the nominal capacity of the tank. A calibration certificate
issued by an approved testing authority shall be provided for the tank and dipstick. The
calibration certificate shall record the serial numbers of the dipstick and the tank;
 The type of spray nozzles, the spacing of the nozzles along the spray bar and the height of the
spray bar above the road surface shall be such that the distribution of the binder over the
sprayed width of the road is of the required uniformity. Nozzles must be so mounted that their
alignment is positively set and maintained. All nozzles on the spray bar shall be of identical
manufacture and rating. The size of nozzles shall not be modified. Nozzles shall be tested
before each separate spray application to check that individual nozzles operate properly and
produce a regular fan-shaped spray. Malfunctioning nozzles shall be cleaned or changed as
necessary. The spray from the end nozzles shall be regulated by baffles to give a full spray
across the whole width of the bar;
 Before each separate application of binder, the spray bar shall be reset to the height required
to ensure the necessary uniformity of nozzle spray overlap (double or triple) and distribution is
maintained. For this purpose the distributor shall be fitted with accurately calibrated and easily
read means of rapidly checking the spray bar height above the road. The spray bar shall be
articulated to facilitate setting parallel to the road camber;

 The spray bar shall be so designed that, while the distributor is in motion, the bar can be
easily and rapidly moved up to 200 mm in a transverse direction to either side of the
distributor;
 The distributor shall be equipped with a spraying lance to undertake work on footways and
irregularly shaped areas of carriageway, and other inaccessible areas where the use of the
spray bar is not practicable;
 The distributor shall be equipped with two pressure gauges and two filters. The filter apertures
shall be not greater than half of the diameter of the smallest aperture of the nozzles. They
shall be capable of rapid detachment and cleaning, which shall be carried out daily or more
frequently if necessary;
 The distributor shall carry a card showing the registration number, the date tested, the test
pressure and temperature, height of spray bar and the type and viscosity of binder used in the
test. It shall also carry charts relating road speed to rate of application of binder so that the
driver can accurately determine the speed required for the rate of application specified;
 Each distributor shall have two serviceable fire extinguishers available at all times.
(i) Depot Spray Test

The calibration method and the limits specified in the depot spray test are the same for all lengths of
spray bar. The spray bar shall be calibrated for each length of bar which is to be used on the Works.
The conditions prevailing during the test shall be comparable to those occurring during normal
operations related to:
 temperature of binder;
 viscosity of binder;
 height of spray bar above test surface;
 pressure in the distribution system;
The apparatus for this test consists of a wheeled trolley carrying a set of removable containers. Each
container is 50 mm wide x 1,000 mm long x 150 mm deep, made of 0.9 mm mild steel sheeting, and
with a capacity of seven (7) litres. The containers extend to a width of 150 mm greater than the full
spray width of the distributor, there being six containers per 300 mm of spray width. The rim of each
container is lipped on one side so that the containers will overlap and the binder will not escape.
Before each test, the containers shall be examined for damage and shall be replaced if such damage
is likely to affect the test.
The trolley shall run on steel rails fastened to the top of a 1,500-litre catch tank, the rails being
horizontal, parallel to the sides of the tank, and sufficiently long to allow the trolley to lie clear of the
spray-bar before the test. The top rim of each container, when fitted on the trolley, shall be parallel to
the rails at the same distance below the nozzles or distributing gear, as the road surface would be
under normal working conditions.
The distributor is backed into position with the spray bar over the catch tank, making sure that the
spray bar is horizontal and at right angles to the rails. The trolley and containers shall rest on the rails
clear of the spray hood. A short preliminary spray is made to ensure that all nozzles are functioning
and that the machine is otherwise in normal working condition.
The trolley and containers are then pushed underneath the spray hood; spraying is commenced and
maintained for a period of time sufficient to almost fill the containers. The trolley is then withdrawn to
the previous position.
The depth of binder in each container is measured by dipping in a steel ruler graduated in millimetres.
Each container is placed in the same position for testing, a convenient place being some 300 mm from
one end. Dipping is done when the froth has settled. The results are expressed as the percentage
deviation from the mean over the effective width of the spray bar. (The effective width of the spray bar
is defined as the sprayed width less a 150 mm margin at each end of the spray bar.)
Individual trays shall not deviate from the mean for transverse distribution by more than ten (10) per
cent.
(c) Water Sprinkler

The water sprinkler shall have efficient spray equipment, capable of spraying a uniform film of water
over the whole area required to be watered.
(d) Mechanical Sweepers or Broom
(i) Drag Brooms

Drag brooms shall be of a size, type and mass that will enable the chippings to be distributed evenly
over the surface without dislodging chippings from the binder.
(ii) Rotary Brooms

An approved rotary broom shall be available at all times during surfacing works. It shall be power
operated, self-propelled or towed.
All sweeping equipment shall be fitted with pneumatic tyres.
(e) Air blowers

Air blowers or compressors shall be designed and operated to assist in the removal of loose or
deleterious material from the surface of pavement layers.
(f) Chip Spreaders

Chip spreaders, whether self-propelled or truck-mounted shall be capable of:
 Spreading the stone uniformly, both transversely and longitudinally, over widths from 1.5m to
4.0m;
 Adjustment to permit variation of the rate of application;
 Stopping and starting without forming a joint line; and
 Keeping pace with the binder distributor.
At least two chip spreaders shall be provided, one of which shall be self-propelled.
Any spreaders that are not self-propelled shall be of a type that can be attached quickly to the rear of
trucks, and operated while being backed over the stone chips being spread.
(g) Rollers
The type and number of rollers shall be subject to the approval of the Engineer for each type of
surface treatment and the proposed programme. Sufficient operational rollers of each of the following
type shall be available on the Works to maintain the required tempo of work:
(i) Pneumatic-tyred Rollers

Pneumatic-tyred rollers shall be of the self-propelled type equipped with smooth flat profile pneumatic
tyres of uniform size and diameter. The mass of the roller shall not be less than 2 tonnes per wheel.
The minimum compaction width shall be 1.5m with a minimum contact pressure of 275 kPa. The
rollers shall be equipped with suitable devices for wetting and cleaning the wheels during operation.
The wheels of the roller shall be so spaced that one pass of the roller will provide one complete
coverage equal to the rolling width of the machine and the tracks of the front wheels and rear wheels
shall overlap. The Engineer, at his discretion, may vary the total operating mass and tyre pressure (to
a maximum of 600kPa). Individual tyre pressures shall not differ by more than 35 kPa from one
another.
(ii) Rubber-soled Flat Rollers

Rubber-soled flat rollers shall be self-propelled, equipped with smooth rubber-soled steel wheels or
rolls. The rollers shall be between 6 and 8 tonnes mass and shall be equipped with suitable devices
for wetting and cleaning the wheels during operation.
The wheels of the roller shall be so spaced that one pass of the roller will provide one complete
coverage equal to the rolling width of the machine and the tracks of the front wheels and rear wheels
shall overlap.
(iii) Steel-tyred Flat Rollers

Steel-tyred flat rollers shall be self-propelled, equipped with smooth steel-tyred wheels or rolls. The
rollers shall be between 6 and 8 tons mass and shall be equipped with suitable devices for wetting and
cleaning the wheels during operation. The Engineer shall determine the mass of the roller required. No
steel-wheeled roller shall be used without the written consent of the Engineer. Steel-wheeled rollers
shall be used only on the first coat of a double surface treatment.
(h) Trucks for Transportation of Chippings

The discharge opening of the trucks that transport the chippings shall be fitted with a low gate or
barrier to trap fines and dust, which may settle from the mass of the chippings during transportation
from the stockpiles, and prevent them being discharged into the chip spreader.
Such accumulations of dust and fines in the bed of the truck shall be removed before the truck is
reloaded.
(i) Mixer for Slurry Seal

No central mixing plant will be allowed. A mobile mixer of a type approved by the Engineer shall be
provided. It may be either a batch type mixer or a continuous type mixer. The paddles of the mixer
shall be so designed as to ensure a complete blending of the constituents of the slurry.
For rapid setting slurry seals, the mixing and application of the slurry shall be done by a mixer
designed to provide a rapid mixing time, and sufficient agitation within the spreading system to prevent
segregation or premature hardening. The mixer shall be capable of continuous mixing and application.
The purpose-designed, continuous-type mixer shall be equipped with precise metering systems to
enable the various constituents to be combined continuously in the prescribed formulation.
(j) Spreader Box for Slurry Seal

A spreader box of a type approved by the Engineer shall be used to spread the slurry. The spreader
box for rapid setting slurry shall be of a proven and approved type, to ensure sufficient agitation within
the spreader system.
The spreader box shall be so constructed that the weight is distributed on metal skids in such a way
that no damage is done to the surface when the box is in operation.
Soft rubber belting shall be attached to the framework in such a way that no spillage of slurry occurs
past the sides of the spreader box when the box is in operation.
The spreader box shall be capable of spreading a uniform application of slurry seal in adjustable
widths from 1.5m to 4.0m, at specified rates, and it must have efficient mechanical means of adjusting
the rates and widths of application specified.

(k) Pre-coating Plant

Where specified, pre-coating of chips may be done in any suitable plant capable of uniformly coating
the chips.
(l) Weighing Devices

Where payment per tonne is specified, the Contractor shall provide and install suitable gauged
weighing devices on the site, in accordance with the Engineer’s requirements. The devices shall
provide a printed report of each measurement including vehicle number; date; time; cargo type; tare
weigh;, loaded vehicle weight; and net cargo weight. Printed measurement tickets shall be verified on
site by the Engineer’s staff and shall be submitted to the Engineer on a daily basis.
(m) Miscellaneous Equipment

Sufficient equipment for handling and hauling chippings, other aggregate and binder shall be provided
to ensure prompt and continuous covering of bituminous materials as specified. The Contractor shall
have available all the necessary ancillary equipment and hand tools, thermometers etc to carry out the
work efficiently.
(n) Reserve Equipment

The Engineer shall be entitled to request reserve equipment if he has reason to doubt the efficiency or
capacity of the equipment provided.
6305 Limitations and General Requirements
(a) Stockpiling of Aggregates

Sites for the stockpiling of chippings shall be prepared in such a manner that no grass, mud, dirt or
other deleterious material will be included when the chippings are loaded for use.
Access to stockpile sites shall be prepared and maintained in such a way that no dirt is conveyed by
vehicle wheels onto the areas to be surfaced or resurfaced whilst chippings are being transported to or
from the stockpiles.
Stockpiles shall be so sited that they will not be exposed to excessive contamination with dust arising
from traffic on the road or access roads. Chippings contaminated to the extent that they contain more
than the allowable percentage of material passing the 0.425 mm sieve shall not be used for surfacing.
(b) Weather limitations

The minimum road surface rising temperatures at which the spraying of the various types and grades
of binder may be done shall comply with the requirements of Table 6305/1.

Table 6305/1: Minimum Road Surface Temperatures for Spraying Binder for Surface Seals
Minimum road surface

Material Type Grade or Class
temperature (ºC rising)
70/100 25
Penetration Grade Bitumen
150/200 20
Cutback Bitumen MC 3000 10
Cationic Spray Grade (60, 65 & 70 %) 10
Bitumen Emulsion
Anionic Spray Grade (60%) 10
S-E1 & S-E2 25
Modified Binders SC-E1 & SC-E2 10
S-R1 25
Spraying shall only be done at the minimum temperature when, in the opinion of the Engineer, the
road surface temperature is rising.
Whenever, in the opinion of the Engineer, the road surface temperature is likely to fall below the
minimum temperatures specified, before the commencement of spraying, no spraying shall be carried
out.
No bituminous work shall be done during foggy or rainy weather. When a cold wind is blowing the
specified temperatures shall be increased by 3ºC to 6ºC as directed by the Engineer.
Conventional slurry shall not be applied at an air temperature of less than 7ºC when temperatures are
rising or less than 13ºC when temperatures are dropping.
Rapid setting slurry may, if so designed, be laid in air temperatures of 4ºC to 40ºC and in damp
conditions.
During hot weather slurry operations shall be suspended when the spreader box or squeegees are
displacing aggregate.
When strong winds are blowing and this is likely to interfere with the proper execution of the work, no
surfacing, especially spraying of binder, shall be done.
When the breaking process is so accelerated as to render the product unworkable (eg. by high
ambient temperatures), or as otherwise prescribed by the Engineer, no surfacing work shall be done.
(c) Moisture Content

No surface treatment shall be placed unless the moisture content of the upper 50 mm of the road base
is less than 50% of the optimum moisture content of the road base as determined by the Engineer. To
prevent the trapping of water in the pavement structure after prolonged or intense rain, no seal or
reseal shall be placed on an existing partly cracked and/or highly permeable surfacing for a period of
at least 24 hours or such extended period as determined by the Engineer.
(d) Curing Periods for Slurry Seals

Unless otherwise indicated in the Particular Specification, the following curing periods shall apply to
the various treatments listed prior to applying a seal or reseal:
 Texturing using fine slurry 6 weeks

 Rapid setting slurry 12 weeks
 Crack sealing 2 weeks
 Repair of distressed patches 6 weeks

(e) Spraying to cease at 15:00 hours

Unless otherwise agreed by the Engineer, and subject to the satisfactory outcome of a trial section, the
Contractor shall programme all spraying operations to cease at 15:00 hours local time each working
day.
(f) Traffic
The Contractor shall comply with the requirements of Division 1500.
(g) Trial Areas

than 1000 square metres using the materials and equipment proposed for the work to demonstrate
compliance with the requirements of this Clause.
(h) Cutting Back of Bitumen

The cutting back of bitumen will only be allowed where authorised by the Engineer and in accordance
with Engineer’s requirements. Only approved kerosene shall be used for cutting back.
The temperature of the bitumen, when the kerosene is introduced, shall not be higher than 140ºC.
When cutting back is done in a bitumen distributor, the kerosene shall not be introduced into the
distributor through the inspection manhole, which shall be kept closed. The kerosene shall be sucked
from 200 litre drums in measured quantities through the bitumen pump and circulated with the bitumen
for a minimum of 45 minutes. During this process all burners shall be shut off and no open flames shall
be allowed near the distributor.
The maximum amounts of kerosene shown in Table 6305/2 shall be added to the penetration-grade
bitumen depending on the road surface temperature at the time of spraying. Lesser amounts than
those indicated may be used if conditions on Site allow the development of sufficient adhesion
between binder, chippings and the existing surface.
Table 6305/2: Addition of Kerosene
Range of road surface Approximate corresponding Maximum addition of Kerosene

temperatures range of ambient air by volume
(ºC) temperatures (ºC) (%)
16 – 24 10 – 16 7
24 – 32 16 – 21 5
32 – 40 21 – 26 3
40 – 48 26 – 31 1
> 48 > 31 0
(i) Heating of Conventional Bituminous Binders

The temperature ranges between which conventional bituminous binders are to be heated fro storage
and spraying shall be as shown in Table 6305/3.

Table 6305/3: Storage and spraying temperature for bituminous binders for Surface Seals
Maximum Storage Temperature Heating and Spraying

Materials (ºC) Temperature (ºC)
< 24 hours > 24 hours Minimum Maximum Recommend
Penetration-grade bitumen
80/100 175 125 165 190 175
150/200 165 115 150 175 165
Cut-back bitumen
MC-3000 155 100 135 155 145
Bitumen emulsions
60 % 60 Ambient Ambient 60 60
65 % 60 Ambient 50 60 60
70 % 60 Ambient 55 65 65
Binders stored in a heated condition shall be kept in a container having a properly functioning
circulatory system and a securely fitting lid. The container shall have a properly functioning built-in
thermometer.
Binders that have been heated above the maximum storage temperatures indicated in Table 6305/3
shall not be used and shall be removed from Site. During spraying, every effort shall be made to
maintain the binder temperature within 5ºC of the recommended spraying temperature.
(j) Heating of Modified Bituminous Binders

The temperatures and time limits for short-term handling, storage and spraying modified bituminous
binders for surface seals as classified in Table 6303/4 shall be as shown in Table 6305/4.
Table 6305/4: Temperature/Time Limits for Modified Bituminous Binders for Surface Seals
Short-term Handling Storage Spraying

Max Max Max Max Max Min Max
Binder Class
Temp Holding Temp Holding Temp Temp Holding
(ºC) Time (hrs) (ºC) Time (hrs) (ºC) (ºC) Time (hrs)
S-E1 (SBR) 180 24 150 240 210 190 8
S-E1 (SBS) 180 24 150 240 185 175 12
S-E2 180 24 150 240 185 175 12
SC-E1/E2 (65% bitumen) 60 24 Ambient > 240 70 50 6
SC-E1/E2 (70% bitumen) 70 24 Ambient > 240 80 50 6
S-R1 165 24 150 240 210 195 4
(k) Preparation of Areas to be Surfaced
(i) General
The areas to be surfaced or sealed shall be cleaned of all dust, dirt, dung, oil, or any other foreign
materials that may be deleterious to the surface treatment.
(ii) New Construction

Where newly constructed road base or shoulder areas are to be surfaced, these areas shall be
checked for compliance with the surface tolerances and all other requirements specified. Any portions
that do not meet these requirements shall first be either corrected or removed and reconstructed,
before they are surfaced.
(iii) Existing surfaces that are to be resurfaced

Existing roads that are to be resurfaced and/or resealed shall, if so specified or ordered by the
Engineer, be prepared for resurfacing in accordance with one or more of the methods described in
Division 6600.

(l) Demarcation of Working Area
(i) New Construction

The Contractor shall demarcate the area of the primed road base to be surfaced by means of setting
out wire, or string lines down each edge of the proposed surfaced width. The control intervals for the
setting out of horizontal curves shall be as agreed by the Engineer.
(ii) Existing surfaces that are to be resurfaced

The centreline of the road or other reference setting out line, as agreed by the Engineer, shall be
established immediately before the tack coat or bituminous binder is sprayed.
(m) Protection of Kerbs, Channels etc.

Kerbs, channels, guttering, manholes, guard rails, bridge railings and any other structures that may be
soiled by bituminous binders during spraying operations shall be covered with suitable plastic sheeting
during spraying operations. The sheeting shall be kept firmly in position by soil, stones or adhesive
tape in such a manner that it will not lift or be blown away during windy conditions but will keep the
areas to be protected fully covered.
The use of paper bags, sand or other materials will not be permitted in lieu of plastic sheeting and the
Contractor shall replace at his own expense any items that have been soiled and cannot be cleaned
entirely.
The painting of soiled surfaces will not be acceptable as a suitable remedy.
(n) Dust Control

Any diversions and construction roads adjacent to any surfacing works shall be kept watered and
damp during all surfacing operations and all dust shall be removed from surfaces before any binder,
aggregate or slurry is applied.
6306 Construction
(a) General
The Contractor shall give adequate advance notice of his intention to proceed with any surfacing
works.
(b) Application of Binders

Bituminous binders shall be applied by means of a binder distributor to the specifications in sub-
clause 6304(b), unless otherwise approved. To prevent surging and spluttering, the tank of the
bitumen distributor shall not be completely emptied during the spraying operation and the area to be
sealed shall be limited to ensure that ten (10) per cent of the nominal capacity of the tank is retained at
the completion of spraying. When the tank contains less than twenty (20) per cent of the nominal
capacity of the tank, spraying shall be done in an uphill direction unless otherwise approved by the
Engineer.
The quantity of bitumen sprayed in any single spray operation shall be governed by the quantity of
chippings and the number of available trucks, which shall be sufficient to ensure the continuous
application of stone behind the distributor.
(c) Joints between Binder Sprays

In order to prevent overlapping at transverse junctions of separate binder applications, the previous
work along the joint shall be covered with twine-reinforced building paper for a sufficient distance back
from the joint to ensure that the spray bar of the bitumen distributor is operating at the required rate
before the unsprayed surface is reached, and also to prevent additional binder application onto the
previously sprayed section. The same method shall be used to ensure a neat joint at the end of the
run.
If in the opinion of the Engineer, the Contractor is unable to apply surfacing to the entire width
specified in a single pass, the Contractor shall apply the surfacing in strips. Adjacent sprays shall
overlap by 150mm. Chippings shall not be placed on the 150 mm overlap before the adjacent strip has
been sprayed. The adjacent strip may not be sprayed before the preceding strip, excluding the 150
mm overlap, has been covered satisfactorily with chippings in compliance with the specifications. As
far as is practicable, the Contractor shall so place the strips that the joint between two adjacent
chipping applications shall fall on the centreline of the road.
(d) Application of Chippings

Chippings shall be applied by means of chip spreaders as described in sub-clause 6304(f). Chip
spreaders shall commence spreading the chippings as closely as possible behind the distributor. The
chip spreader shall be operated in such a manner that the binder shall be covered with chippings and
the wheels of the chip spreader or truck do not pass over the uncovered binder. All chippings shall be
spread as soon as possible but no later than ten (10) minutes after the binder has been sprayed.
Any areas deficient in chippings shall have additional material added to leave the carpet with a single
layer of chippings lying shoulder to shoulder. It is essential to ensure that only one layer of chippings is
applied and every care shall be taken to avoid over-application of chippings.
The finished surface shall be well-knit and have a uniform appearance free of roller-tyre marks.
All chippings contaminated by oil, fuel or grease shall be removed and replaced by clean chippings.
All loose chippings shall be broomed off the surface with a rotary broom or hard brooms as directed by
the Engineer.
(e) Rate of application to be determined by the Engineer

The actual rates of application of binder and chippings to be used in construction will be determined by
the Engineer, after testing of the chippings that the Contractor proposes to use for the surface
treatment, and prior to any surfacing work being carried out.
(f) Single and double surface treatment – General Requirements
(i) First application of binder and chippings

A first application of binder consisting of the type and grade of binder specified in these Specifications
under each of the appropriate Clauses for each type of bituminous surface treatment, or in the
Particular Specifications, shall be sprayed on the properly cleaned and prepared road base or existing
surface over the full specified width of the surfacing.
Immediately after the binder has been sprayed, it shall be covered with chippings of the size specified
in these Specifications under each of the appropriate Clause for each type of bituminous surface
treatment.
(ii) Initial Rolling of Chippings

As soon as the chippings have been applied, rolling shall commence with a self-propelled pneumatic-
tyred roller with a loading 2.0 tons per wheel working parallel to the centreline of the road from the
shoulders towards the crown of the road until the whole surface has been covered at least three (3)
times with the wheels of the roller, or five times in the case of the single surface treatment and surface
treatments with chippings and slurry seal.

(iii) Broom Drag and Final Rolling of Chippings

This Clause shall not be applicable to single surface treatments without a fog spray.
After the bituminous binder has set-up sufficiently to prevent any chipping from being dislodged, the
surface shall be slowly dragged with a broom drag in order to ensure even distribution of the
chippings. If there are areas that are deficient in stone chips, additional material shall be added by
hand so as to leave the carpet with one layer of stone shoulder to shoulder.
If there are areas having an excess of stone chips, such excess shall be removed by hand so as to
leave the carpet with one layer of stone shoulder to shoulder. The importance of applying only a single
layer of stone is stressed. Every care shall be taken to avoid an over-application of stone.
When the spreading of stone chips is complete, the surface shall be rolled with a pneumatic-tyred
roller with a loading 2.0 tons per wheel until the whole surface has been covered at least four (4) times
with the wheels of the roller. Except in the case of single seals, final rolling shall be done with a flat
steel-tyred roller of 6 to 8 tons mass, working parallel to the centreline of the road from the shoulders
towards the crown of the road, until every portion of the area concerned has been covered by two (2)
passes of the roller, provided only a minor amount of crushing of the chippings takes place. If in the
opinion of the Engineer general crushing occurs under the rollers, such rolling shall be stopped
regardless of the number of passes completed by the roller.
The surface shall be well knit and have a uniform appearance free of roller tyre marks. All chippings
contaminated by fuel, oil or grease shall be removed and replaced with clean stone.
(g) Fog Spray

If required by the Particular Specifications or if so directed by the Engineer, a fog spray of 60% or 30%
anionic or cationic emulsion shall be applied to the surface of the chippings by means of a pressure
distributor at the required rate.
(h) Blinding
If directed by the Engineer, a light blinding layer of washed natural sand or crusher sand shall be
applied by the Contractor to prevent chippings from being picked up by traffic. The blinding layer shall
be spread evenly over the entire area indicated. If so required by the Engineer, the layer of sand shall
be spread by means of hand brooms.
6307 Rates of Application

All binders; chippings and other aggregates; and slurry used in the various types of bituminous surface
seals shall be applied at the rates of application as approved by the Engineer after tests on the
materials proposed for use, within a tolerance specified in Clause 6313.
No payment will be made for bituminous binder material applied in excess of the specified rate plus
the permitted tolerance; or at a rate lower than the specified rate, minus the permitted tolerance
unless, in the opinion of the Engineer, such over-spray or under-spray can be satisfactorily corrected
in the case of a first application by the adjustment of the application rate of the second spray, and if
such correction is effected.
Whenever the terms “net bitumen” or “net quantity of bitumen” are used in these specifications to
specify the rate of application of the binder for conventional or homogeneous modified binder, they
O
shall mean net bitumen cold at a temperature of 20 C, including any volatiles normally contained but
shall not include any water, emulsifying agents or volatile oils added in the production of bitumen
emulsions or cut-back bitumen. Non-homogeneous modified binders (S-R1), however, shall be
specified at spraying temperature.
Unless otherwise specified, the nominal rates of application of bituminous binders given in further
sections shall be measured at spraying temperature, as will be the variations in application rate.
The nominal rates of application are for tendering purposes only and will not necessarily be used in
construction. The actual rates of application to be used on the site shall in all cases be as instructed by
the Engineer.
Appropriate approved conversion factors shall be used for calculating net bitumen from binder at the
spraying temperature.
6308 Areas Inaccessible to Mechanical Equipment

Areas inaccessible to mechanical equipment shall be constructed as follows:
(a) Prime coat/Tack coat

The prime/tack coat shall be applied to the area to be surfaced by hand spraying under the close
supervision of an experienced person. The application of prime/tack coat shall be controlled in order to
achieve a uniform application at the rate specified. The type of prime/tack coat material and the rate of
application thereof shall be subject to the Engineer's approval.
Each area that is to be surfaced shall be screened off by means of fibre-reinforced paper, so that only
the area to which the binder is to be applied will be exposed.
The binder shall be applied by means of hand-spray lance which should form part of the bitumen
distributor equipment complying with the requirements specified in sub-clause 6304(b), or by any other
hand spray operation as approved by the Engineer.
(b) Binders for Surface Seals

Bituminous binders for surface seals shall be constructed by means of mechanical equipment, unless
otherwise approved. Binders, and particularly bitumen-rubber binders, shall be applied using binder
distributors which have been specially adjusted for accurately applying the binders in restricted areas
in accordance with the specified requirements.
Hand–spray equipment may be used only with the written approval of the Engineer and then only in
accordance with approved methods under the strict supervision of experienced personnel; and with
equipment suitable for performing the work in accordance with the specified requirements.
(c) Aggregate Chippings

Aggregates used for surface seals in restricted areas shall be of the same size as the adjacent
surfacing and shall be spread by hand. The chippings shall be rolled to the satisfaction of the Engineer
with the most effective rollers that can be used in the area in question, and thereafter the excess
chippings shall be removed by means of hand brooms. If a double surface treatment is required, the
specified penetration spray shall be applied and the second layer of chippings applied, rolled and
broomed. Any specified fog spray of bitumen emulsion shall be applied within 48 hours.
(d) Slurry
Where the surfacing layer consists of an application of aggregate with slurry, the slurry shall be applied
3 2
to the surface of the layer constructed at a rate of between 0.003 and 0.004 m /m or as instructed by
the Engineer. This shall be done at the same time as the final slurry application on the other portions
of the work to obtain a uniform appearance.

(e) Bituminous Mixture

Where a premixed bituminous mixture is specified for surfacing in inaccessible areas as shown on the
Drawings, or as instructed by the Engineer, a mixture shall be prepared consisting of the following
components and proportions:
 9.5mm nominal size aggregate 1 part

 6.7mm nominal size aggregate 1 part
 Crusher sand 1 part
The aggregate and sand shall be mixed with a 60% stable-mix grade emulsion with the net quantity of
bitumen between 75 and 90 l/m³ aggregate mix. The ingredients shall be mixed in a suitable concrete
or other type of mixer with suitable heating mechanism by gas flame or other means, while the mixer is
rotating.
The aggregate and sand shall be placed in the mixer and heated to 100ºC while mixing after which the
bituminous emulsion shall be added. Mixing shall continue until the aggregate is uniformly coated with
bitumen.
Prior to spreading the mixture, the surface shall be prepared by painting with one layer of bituminous
emulsion which shall be allowed to dry. The mixture shall be placed in the areas to be sealed and
screeded off in a layer of uniform thickness. After the emulsion has broken and the layer has attained
sufficient stability, it shall be rolled with suitable compaction equipment.
The thickness of the layer shall be the same as that of the adjacent seal.
6309 Opening to Traffic

The Engineer shall be responsible for determining when any surfacing is to be opened to public traffic.
The road shall not be opened to traffic until the binder has set sufficiently to retain the chippings, or in
the case of slurry seals, the slurry has set sufficiently that it will not be picked up by the wheels of
passing traffic.
The Contractor shall not allow any construction equipment, which is likely to cause damage, over the
completed surface treatment.
The Contractor shall display speed restriction signs in accordance with Division 1500 and the
instructions of the Engineer.
6310 Defects
Where in the opinion of the Engineer, any excessive loss of aggregate or bleeding of the road surface,
that may occur during the course of the Contract or during the Defects Liability Period, can be
attributed to the Contractor not observing any of the requirements of the Specifications; not using the
correct rates of application; or any other omission or fault on the part of the Contractor; any corrective
work ordered by the Engineer shall be at the Contractor's own cost including the supply, pre-coating,
stockpiling at selected sites, and later removal if not used, of any chippings or other aggregate
reserved for corrective work during the Defects Liability Period or thereafter.
Before commencing any repair works, the Contractor shall obtain the approval of the Engineer for the
proposed repair methods, which shall be based on the requirements of this Clause.
Where the reason for loss of aggregate or bleeding cannot, in the opinion of the Engineer, be
attributed to any fault or neglect on the part of the Contractor, the Employer shall pay at the tendered
prices for the cost of any remedial measures taken on the instructions of the Engineer.
(a) Surface Defects

Before any treatment is carried out, the area to be treated shall be cleaned and prepared; and any
major defects shall be repaired as specified in the Division 6600.
(i) Treatment Type 1

This treatment shall be applied where the existing surface is deficient in binder.
The treatment shall consist of the application of a fog spray of a specified grade of emulsion to the
existing surface by means of a pressure distributor at the rates of application as directed by the
Engineer in widths that may vary from 0.5 m to 4.0 m.
(ii) Treatment Type 2

This treatment is intended for application where marked differences in texture occur in the existing
bituminous surface in order to obtain a uniform texture before resealing.
A tack coat of the specified type and grade of emulsion shall be applied to the surface as specified in
Division 6200 followed by an application of double washed crusher sand. The crusher sand shall be
the medium grade specified for slurry in Table 6303/15 but shall be on the coarse side of the grading
envelope.
The nominal rates of application shall be:
 Emulsion 0.7 litre net bitumen/m²

3 2
 Aggregate 0.0035 m /m
The actual rates of application shall be as instructed by the Engineer. It is likely that spraying and
spreading shall be carried out in narrow bands varying in widths from 0.5 m to 4.0 m. The emulsion
shall be allowed to break before the aggregate is applied. As soon as the aggregate has been applied,
the distribution thereof shall be corrected by light hand-brooming or by means of a light broom drag.
Rolling shall be carried out as specified in 6304(g). Any excess aggregate remaining on the road after
it has been opened for two (2) days or more shall be removed.
(iii) Treatment Type 3

This treatment shall be used when an existing open-textured or cracked surface requires treatment by
a bituminous slurry.
Prior to treatment with the slurry, the surface shall be sprayed with a tack coat of 30% bitumen
emulsion at the rate prescribed by the Engineer.
A distinction shall be made in respect of the payment for the following two methods of construction:
 Where slurry can only be applied by hand methods; or where the Engineer so directs; or
where it is specified that the slurry shall be applied by hand methods.
 Where the slurry can be applied mechanically with a spreader box.
 The slurry shall be prepared, mixed and applied as specified in sub-clause 6318(e) with the
following exceptions:
 Slurry to be applied by hand shall be mixed in a suitable concrete mixer.
 The slurry shall, in the case of application by spreader box, be applied in a single layer at a
nominal rate for tendering purposes of 0.004 m³/m².
When applied by hand with brooms or rubber squeegees, the slurry shall be worked into cracks and
other open areas until a sound uniform surface is obtained.

(b) Bleeding
Bleeding shall be corrected by one or more of the methods described herein, as may be ordered by
the Engineer:
(i) General
The remedial work shall be carried out as soon as possible after bleeding occurs.
All operations to correct bleeding shall be carried out only when the road temperature is high enough
to promote adherence of any aggregate that may be applied.
If only half the road width is to be treated, the application of the remedial works shall be finished in a
neat line on the centreline of the road
Before opening any rectified work to traffic, all the loose aggregate shall be swept off the surface.
It is essential to use a heavy pneumatic roller for this work. Rolling shall continue until the Engineer is
satisfied that the aggregate has been properly embedded. No rolling shall be done in wet weather,
cold weather or early in the morning when the surface is cold.
Notwithstanding the following methods of treatment, the Engineer may order any surfacing, which has
not been properly constructed to be removed and replaced. The removal of the surfacing shall be
done so as avoid damaging the existing road base. All aggregate and binder shall be removed either
by grader or by hand tools and any damage done to the surface shall be repaired to the satisfaction of
the Engineer.
Bleeding shall be corrected by one or more of the methods described, as instructed by the Engineer.
(ii) Method 1: Single seal with slurry: Light bleeding

Nominal 6.7 mm aggregate conforming to the requirements of Table 6303/10 shall be used. If required
by the Engineer, the aggregate shall be coated as described in Sub-clause 6303(b)(iv) with an
approved precoating fluid by using 10 to 12 l/m³. If the binder of the existing surface has an oxidised
film or if the road has been used by traffic for some time, it shall be treated either by brushing in power
paraffin to soften the surface of the binder, or the surface shall be softened up with gas burners. This
work shall only be done on hot days. The aggregate shall be applied to the surface immediately at the
rate of 0.004 m³/m² and rolled with a heavy pneumatic-tyred roller until the aggregate is firmly
embedded. All loose aggregate not embedded shall be broomed off the road before it is opened to
traffic. When opening the road to traffic, the affected areas shall be demarcated with traffic cones and
speed limit signs for the first two days, care being taken to remove all loose aggregate daily. Areas
where whip-off is excessive after the above treatment has been carried out shall be retreated in
accordance with the Engineer’s instructions.
(iii) Method 2: Single seal with slurry: Severe bleeding

The method to be used shall be the same as Method 1, except that the aggregate shall be nominal
sized 9.5mm or 13.2mm and they shall be spread at the rate of 0.007 m³/m² and 0.010 m³/m²
respectively. If only half the road width is to be treated, the application of aggregate shall be finished in
a neat line on the centre line of the road.
(iv) Method 3: Bleeding single or multiple seals

If the surface is non-uniform, ie partly bleeding and partly coarse-textured, the surface shall be
rectified by pre-treating the coarse areas in accordance with Clause 6310(a)(ii) to obtain a uniform
surface, which shall then be covered with a single seal in accordance with the standard Specifications.
The type of aggregate to be used shall be determined by the Engineer. The pre-treated surface shall
be inspected and the size of aggregate and the rates of application of the tack coat and aggregate,

which the surface can accommodate, shall be established. Methods 1 or 2 shall be used if so ordered
by the Engineer.
(c) Loss of Aggregate

Where loss of aggregate occurs, the following measures shall be applied immediately:
 The affected sections of the road shall be closed to traffic using appropriate roads signs in
accordance with this Specification. All loose aggregate shall be removed from the road surface
by brooming using stiff brooms.
 The Engineer shall determine the extent and nature of the defective section and shall instruct
the Contractor to execute one or more of the following measures.
(i) Slight loss of aggregate

If so ordered by the Engineer, slight loss of aggregate shall be treated by application of a fog spray.
The surface to be repaired shall be clean and dry, and a spray grade emulsion shall be applied at a
2
rate of 0.55 l/m or other such rate as may be ordered by the Engineer.
(ii) Loss of aggregate in limited areas due to low temperature

The areas to be treated shall be demarcated by the Engineer. If so ordered by the Engineer, any
remaining aggregate within these areas shall be removed using hand-equipment. Heating apparatus
may be used as instructed by the Engineer. Thereafter the areas shall be resurfaced as described in
Clause 6308.
Loss of aggregate shall be corrected in accordance with the requirements of the Engineer, using a fog
spray. The surface to be repaired shall be clean and dry and a fog spray of 30 % anionic or cationic
2
spray-grade emulsion shall be applied at the rate of 0.4 l/m or other such rate as may be approved by
the Engineer.
(iii) Loss of aggregate in large areas due to low temperature

The remaining aggregate shall be bladed from the road surface as soon as possible and the affected
area shall be resurfaced as prescribed by the Engineer.
(iv) Loss of Aggregate in areas due to binder deficiency

As soon as the temperature of the road surface is within the prescribed limits, a fog spray of diluted
bitumen emulsion shall be applied at the specified or approved by the Engineer. An additional layer of
aggregate shall then be applied by a mechanical spreader at a rate sufficient to replace the loss of
aggregate. The completed layer shall then be rolled to the satisfaction of the Engineer with pneumatic-
tyred rollers as specified in sub-clause 6304(g). When the binder has set sufficiently, all surplus
aggregate shall be swept off the road surface with brooms.
6311 Maintenance
The Contractor shall maintain the bituminous surface until the Employer finally accepts the work. Any
damage occurring to the surface or any defects which may develop before the maintenance certificate
is issued (fair wear and tear excepted) shall be corrected by the Contractor at his own expense and to
the requirements of the Engineer.
6312 Damage to the Road Surface by Third Parties

The Contractor shall repair damage to the road surface caused by third parties. Such repair shall be
carried out in accordance with the relevant sections of the Specifications as directed by the Engineer.
Except and to the extent that the occurrence resulting in the damage is a consequence of an act or
omission by the Contractor, the cost of such repairs, as determined by the Engineer, will be paid to the
Contractor by the Employer.

6313 Tolerances and Finish Requirements

The completed bituminous work shall comply with the following requirements regarding surface
tolerances and finish.
(a) New Construction
(i) General
Any areas, which show signs of bleeding after the section has been opened to traffic, shall be
corrected as specified in Clause 6310. Corrective work shall be carried out in such a manner as to
blend in colour, texture and finish with adjacent work.
The completed bituminous surface seal shall be free of corrugations or any other wave effects.
(ii) Level and Grade

The requirements relating to the road base on which the surfacing is constructed shall apply.
(iii) Width
The edges of the surfacing shall be true to line with a maximum deviation from the specified edge line
of 20 mm.
(iv) Cross Section

(v) Surface Regularity

(b) Resealing Work on Existing Surfaces

The completed surfacing shall be of uniform texture without gaps or patches and shall be free from
any loose aggregate or bitumen spillage.
Any areas that show signs of bleeding after the section has been opened to traffic shall be corrected
as specified in Clause 6310. Corrective work shall be carried out in such a manner as to blend in
colour, texture and finish with adjacent work.
The completed seal shall be free from corrugations or any other wave effect where depressions are
preceded and followed by humps or ridges no matter how small the distance between the top of the
hump to the bottom of the preceding or following depression.
The edges of the completed seal shall be continuously true to line with a maximum allowable deviation
from the specified edge line of 20 mm.
(c) Rate of Application

The maximum permissible variation from the rates of application of bituminous binders, chippings,
other aggregates or slurry, as ordered by the Engineer, shall be plus or minus 5% of the rate of
2
application required for the aggregates, and plus or minus 0.06 l/m net bitumen cold (20ºC) for
conventional or homogeneous modified binders and within a tolerance of plus or minus 5% for non-
homogeneous binders at spraying temperature.
Where the viscosity of the binder actually in use (at spraying temperature) varies from that at which
the distributor was calibrated, or for any other reason, the Engineer may order the transverse
distribution of the spray bar of the distributor to be verified in accordance with the Depot Tray Test
(Sub-clause 6304(b)(i)), before the binder is applied. The coefficient of variation (100.s/x) of the spray
applications calculated for 100 mm strips of the spray bar (excluding 300 mm strips on each side) shall
not exceed 12% for any one such test ordered by the Engineer. In order to achieve minimum lot sizes
the Engineer may combine sub-lots of the same population.
6314 Testing
(a) Process Control

The minimum testing frequency that will be required by the Contractor in terms of Clause 1202 for the
purpose of process control shall be as given in Table 6314/1.
Table 6314/1: Minimum testing frequencies for Surface Seals

Test Minimum Testing Frequency
Materials
Grading of chippings One test every 250 m³
Los Angeles Abrasion One test every 1000 m³
Flakiness One test every 250 m³
Soundness One test every 1000 m³
No testing required for process control, but the provisions
Bituminous binders for testing in Clause 6303(a) shall apply upon delivery at
the Site.
Complete records to be kept of actual measurements
Application rates made of quantities of materials applied and rates of
application.
Construction Tolerances
Width One test every 100 m, after every spray run
Cross section All rough areas to be checked

Routine inspection and testing will be carried out by the Engineer to test the materials and
workmanship provided, for compliance with the requirements specified in this Division.
Any materials or workmanship that do not comply with the requirements specified, shall be removed
and replaced with materials and workmanship complying with the Specifications or, if the Engineer
permits, be repaired as specified in Clauses 1206 and 6310, so that after being repaired it shall
comply with the requirements specified.
6315 Single Surface Seals

This Clause covers all the work in connection with the construction of single bituminous surface seals
for new road construction and for resealing of existing roads.
The general provisions for surface seals specified in Clauses 6301 to 6314 of this Division shall apply
equally to the work covered by this Clause and shall not necessarily be repeated or specifically
referred to in this Clause.
(a) Materials
The binders (conventional and modified) and aggregate for single surface seals shall comply with the
requirements of Clause 6303.
The ALD of the aggregate chippings shall comply with the requirements in Table 6315/1.

Table 6315/1: Chippings - Average Least Dimension (ALD)
Nominal size (mm) Minimum ALD (mm)

19.0 12.0
13.2 8.2
9.5 5.9
(b) Construction
(i) Application of Binder and Chippings

The binder and chippings of the grade and size specified in the Bill of Quantities or ordered by the
Engineer, shall be applied in accordance with Clause 6306 and 6307.
The nominal rates of application given in Table 6315/2 shall be used for tendering purposes only. The
actual rates of application shall be as determined by the Engineer.
Table 6315/2: Nominal Application Rates for Chippings and Conventional Binders (Tender
purposes only)
Nominal application rates

Nominal Chipping Size
Chippings Net Cold Binder
(mm) 3 2 2
(m /m ) (l/m )
19.0 0.014 1.6
13.2 0.010 1.4
9.5 0.007 1.0
6.7 0.005 0.8
(ii) Initial rolling
Initial rolling shall be carried out as specified in sub-clause 6306(f).
(iii) Final rolling

The final rolling shall be done as specified in sub-clause 6306(f).
(iv) Fog Spray

If directed by the Engineer, a fog spray shall be applied to the surface of the chippings in accordance
with sub-clause 6306(g).
(v) Blinding
If directed by the Engineer, a light blinding layer of sand shall be applied to the surface of the
chippings in accordance with sub-clause 6306(h).
(vi) Pre-coating of Chippings

If directed by the Engineer, the chippings shall be pre-coated with a pre-coating fluid as provided by
sub-clause 6303(b)(iv).
(vii) Work in Areas Inaccessible to Mechanical Equipment

The provisions of Clause 6308 shall apply.
(c) Opening to Traffic

Unless so approved by the Engineer, the road shall not be opened to traffic until the morning following
the completion of the surface treatment when the binder is stiff. In hot climates, the Engineer may
instruct the Contractor to cool the binder by spraying with water before the road is opened to traffic.
6316 Double Surface Seals

This Clause covers the supplying and furnishing of materials for the construction of double bituminous
surface treatments.

The double surface treatments shall be constructed using either:
 19.0 mm and 9.5 mm chippings; or

 13.2 mm and 6.7 mm chippings; as shown in the Bill of Quantities.
(a) Materials
The binders (conventional and modified) and aggregate for double surface seals shall comply with the
requirements of Clause 6303.
The ALD of the first layer of aggregate chippings shall comply with the requirements in Table 6315/1.
The maximum ALD of the second layer of chippings shall be not more than 50% of the ALD of the
respective first layer.
(b) Construction
(i) Application of the First Layer

Binders and chippings, of the type and grade specified in the Bill of Quantities or ordered by the
Engineer, shall be applied in accordance with Clauses 6306 and 6307.
Table 6316/1: Nominal Rates of Application for the First Layer (Tender purposes only)
Nominal rates of application

Chippings Conventional Binder Modified Binder (S-R1)
(mm) 3 2 2 2 #
(m /m ) (l/m ) * (l/m )
19.0 0.013 1.0 1.8
13.2 0.009 0.8 1.6
Note: * net cold bitumen; # at spray temperature
(ii) Application of the Second Layer

Table 6316/2: Nominal Rates of Application for the Second Layer (Tender purposes only)

Chippings Conventional Binder
(mm) 3 2 2
(m /m ) (l/m ) *
9.5 0.006 1.0
6.7 0.005 0.8
Note: * net cold bitumen
The timing for the second application of binder shall be dependent on the type of binder used for the
first application. For penetration-grade bitumens used for the first seal application, the second
application shall take place within 48 hours after the application of the first layer. For cutback bitumen
(MC 3000) used in the first application, the second layer shall be applied not less than twenty (20)
days after the application of the first layer to allow for evaporation of the cutter and breaking of the
binder.

(iii) Initial Rolling

Initial rolling for both layers shall be carried out as specified in sub-clause 6306(f).
(iv) Broom Drag and Final Rolling of Aggregate

Dragging and final rolling of aggregate for both layers shall be carried out as specified in sub-clause
6306(f).
After application of the steel-tyred roller, under no circumstances should the first layer be opened to
traffic before application of the second layer. If for any reason traffic is allowed to pass over the first
layer, the layer shall be re-rolled to the satisfaction of the Engineer before the application of the
second layer.
(v) Fog Spray

If required by the Particular Specifications or if so directed by the Engineer, a fog spray shall be
applied to the surface of the chippings in accordance with sub-clause 6306(g).

sub-clause 6306(f).

the completion of the surface treatment when the binder is still stiff. In hot climates, the Engineer may
Under no circumstances should the first layer be opened to traffic before application of the second
layer (see sub-clause (b)(iv) of this Clause).
6317 Triple Seal Surface Treatment

This Clause covers the supplying and furnishing of materials for the construction of triple bituminous
surface treatments.
The triple surface treatments shall be constructed using either:
 26.5 mm, 13.2 mm and 6.7 mm chippings, or

 19.0 mm, 9.5 mm and 6.7 mm chippings, as shown in the Bill of Quantities.
(a) Materials
The binders (conventional and modified) and aggregate for triple surface seals shall comply with the
requirements of Clauses 6303.
The maximum ALD of the second and third layers of chippings shall be not more than 50% of the ALD
of the respective first and second layers.
(b) Construction
(i) Application of the First Layer


The nominal rates of application given in table 6317/1 shall be used for tendering purposes only. The
Table 6317/1: Nominal Rates of Application for the First Layer (Tender purposes only)

Chippings Conventional Binder Modified Binder (S-R1)
(mm) 3 2 2 2
(m /m ) (l/m ) * (l/m ) #
26.5 0.020 1.4 2.5
19.0 0.013 1.0 1.8
Note: * net cold bitumen; # at spray temperature
(ii) Application of the Second and Third Layers

The nominal rates of application given in table 6317/2 shall be used for tendering purposes only. The
Table 6317/2: Nominal Rates of Application for the Second and Third Layers (Tender purposes
only)

Chippings Conventional Binder
(mm) 3 2 2
(m /m ) (l/m )*
13.2 0.009 1.2
9.5 0.006 1.0
6.7 0.005 0.8
Note: *net cold bitumen
Timing for the application of the second and third layer will be binder dependent. If the underlying layer
is constructed with penetration grade bitumen the subsequent layer shall be added within 48 hours.
For layers constructed with MC 3000, the subsequent layer shall be applied not less than twenty (20)
days after application of the underlying layer.
(iii) Initial Rolling of the Second and Third Layers

Initial rolling of the second and third layers of aggregate shall be carried out as specified in sub-clause
6306(f).
(iv) Broom drag and Final Rolling of the Second and Third Layers
Dragging and final rolling of the second layer of aggregate shall be carried out as specified in sub-
clause 6306(f).
(v) Fog Spray

If directed by the Engineer, a fog spray shall be applied to the surface of the chippings in accordance
with sub-clause 6306(g).

sub-clause 6306(f).

the completion of the surface treatment when the binder is still stiff. In hot climates, the Engineer may
6318 Single Surface Treatment with Slurry (Cape Seal)

This Clause covers the construction of a bituminous surface treatment consisting of a first application
of a bituminous binder, spreading of 19.0 mm or 13.2 mm chippings as specified, a further application
of bituminous binder coat and the application of a bituminous slurry in one or two coats.

(a) Materials
The materials shall comply with the requirements of Clause 6303.
(i) Chippings
(ii) Binder for First Application

The first application of binder shall consist of one of the following binders, whichever is specified in the
Particular Specifications or as ordered by the Engineer:
 70/100 penetration grade bitumen;

 150/200 penetration grade bitumen;
 MC-3000 cut-back bitumen;
 60%, 65% or 70% spray-grade emulsion
(iii) Binder for Second Application

The second application of binder shall consist of one of the following binders, whichever is specified in
the Particular Specifications or as ordered by the Engineer:
 30% spray-grade emulsion, or

 60% spray-grade emulsion.
(iv) Binder for Slurry

The binder used for slurry shall be an anionic or cationic stable-grade emulsion (60% bitumen).
(b) Construction before Application of Slurry

Table 6318/1: Nominal Application Rates for Chippings and Conventional Binders (Tender
purposes only)
Nominal application rates

Nominal Chipping Size Conventional Binder
Chippings 2
(mm) 3 2 (l/m ) *
(m /m ) st nd
1 Application 2 Application
19.0 0.013 1.1 0.33
13.2 0.009 0.6 0.33
Note: * net cold bitumen
(c) Application of First Layer of Binder and Chippings

The binder and chippings of the grade and size specified in the Bill of Quantities or ordered by the
(i) Initial Rolling

Initial rolling shall be carried out as specified in sub-clause 6306(f).
(ii) Broom Drag and Final Rolling of Aggregate

The final rolling shall be done as specified in sub-clause 6306(f).

(d) Second Application of Bituminous Binder

The second application of binder shall be done at least 2 days after the first application of binder and
chippings.
(e) Application of Slurry
(i) Condition of Surface

The surface shall be cleaned to remove all dust, mud, leaves, etc. and shall have a uniform closely
knit appearance, with edges trimmed correctly to the specified width.
The surface shall be rolled once with a light flat-wheeled roller immediately prior to the application of
the slurry in order to depress any chippings that may have been disturbed.
(ii) Timing of Slurry Application

The slurry shall be applied only after the second application of binder described in sub-clause 6318(d)
has cured but in any case not less than two (2) days after the second application.
(iii) Composition of Slurry

The slurry shall consist of a mix of fine, medium or coarse slurry aggregate ordered by the Engineer
and specified in Table 6303/15 together with a 60% stable-grade emulsion, filler and water in the
proportions as directed by the Engineer. The following nominal proportions by volume shall apply for
tendering purposes only:
3
 Slurry Aggregate (saturated volume) 1m
 Stable-grade emulsion at mixing temperature {state type} 260 l
 Cement 0.01 m³
 Water 235 l
If specified in the Particular Specifications, the following nominal proportions by mass shall apply for
tendering purposes only:
 Slurry Aggregate (dry) 100

 Stable-grade emulsion 20
 Cement 1.5
 Water 15
The saturated volume of slurry shall be determined by applying a correction for bulking of moist
aggregate, as described in Pay Item 63.13.
(iv) Mixing of Slurry

The slurry shall be mixed in a mixer of a type described in sub-clause 6304(i).
Material which, in the opinion of the Engineer, is not properly mixed or in which the emulsion shows
signs of having broken during mixing shall not be applied to the road.
The slurry consistency when measured in accordance with ASTM D 3910 Section 6.1 shall be
between 30 mm and 40 mm in order to achieve the required workability.
 Batch Mixing
All the constituents of the slurry shall be accurately proportioned and due care and attention shall be
given to the sequence in which the ingredients are introduced into the mixer and to the period of
mixing. Mixing shall be continued until the materials in each batch are thoroughly blended.
 Continuous Mixing
Aggregate and filler contained in separate bins shall be fed through metering devices at controlled
rates to the mixer. Water and bitumen emulsion contained in separate tanks shall similarly be pumped

to the mixer at controlled rates through metering devices. The mixing of the slurry shall be at a suitable
rate adjusted to ensure complete blending of the ingredients and uniformity of mix.
(v) Application of Slurry

Before slurry is applied, the road surface shall be thoroughly cleaned and lightly sprinkled with water
but no free water shall be present on the surface when the slurry is applied.
The slurry shall be applied in two layers in the case of 19.0 mm chippings and in one layer in the case
of 13.2 mm chippings, unless otherwise specified in the Particular Specifications or ordered by the
Engineer.
The nominal rate of application of slurry shall be as follows for a seal using:
 19.0 mm chippings (total for two layers) 0.008 m³/m²

 13.2 mm chippings (for one layer) 0.006 m³/m²
If specified in the Particular Specifications, the nominal rate of application of the slurry by mass shall
be as follows for a seal using:
 19.0 mm chippings (total for two layers) 0.005 m³/m²

 13.2 mm chippings (for one layer) 0.004 m³/m²
The rate of application of slurry shall be measured in cubic metres of fine aggregate (saturated
volume) contained in the slurry applied, per square metre of surfacing.
The nominal rates of application given above are intended for tendering purposes only and the actual
rates of application on the Site shall be as directed by the Engineer.
When the slurry is applied in two layers, the first layer of slurry shall be struck off level with the tops of
the stones in the aggregate layer so that, after application, the tops of the stones will be just visible.
The second layer of slurry shall not be applied until the first layer has dried. If required by the
Engineer, the Contractor shall open the road to traffic before the second layer of slurry is applied.
Rolling of the slurry shall commence after the slurry has dried sufficiently unless otherwise approved
by the Engineer. Each layer of slurry shall be roller-compacted by at least three roller passes with a
27-ton pneumatic-tyred roller. However, the second layer shall be compacted until the required in-situ
water permeability is less than 1.0 litre/h when measured by means of an approved method. The
second layer shall be applied only after sufficient time has been allowed for the first layer to cure. The
Engineer will decide on the time necessary for proper curing, which will in any case be not less than
24 hours.
The surface shall be thoroughly cleaned of all dust, dirt or foreign materials before the second layer of
slurry is applied.
For seals using 13.2 mm nominal sized chippings, the slurry shall be applied in one layer only. The
slurry shall also be struck off so that the tops of the stone chippings will be just visible after the
emulsion has set and cured.
When the slurry is applied, the squeegee operators shall be allowed to complete the spreading of
each batch discharged onto the road, using squeegees, before the next is discharged.
Slurry shall be spread only by hand and not with a spreader box. In order to adequately fill the voids
with slurry, the squeegees shall be applied in a multi-directional fashion.
The Contractor shall ensure that either edge of the road surface is finished to the specified widths and
lines. All stones dislodged in the process of applying the slurry shall be removed on the same day on
which the slurry seal has been applied. All spillage of slurry or excess slurry shall be neatly removed
from the road and buried. The second layer of slurry shall extend to the edge of the primed surface as
indicated on the Drawings.
The slurry batch shall be discharged onto the road in small increments by means of a chute. The rate
of application shall be measured by mass in kilogram of fine aggregate, contained in the slurry applied,
per square metre of surfacing.
The slurry shall be applied to the full road width in one application. If so ordered by the Engineer, the
slurry may be applied in half-widths of road, provided that the work is so programmed that the slurry is
applied to both half-widths on two successive days in order to complete a section of full road width in
two days.
Any damage to the slurry seal by rain or traffic before the slurry has cured shall be rectified at the
Contractor’s own cost.
6319 Sand Seals

This Clause covers the construction of bituminous sand seals.
(a) Materials
The materials shall comply with the requirements of Division 6303.
(i) Binders
The types and grades of binder used shall be as specified in the Particular Specifications, in the Bill of
Quantities or ordered by the Engineer.
Amongst others, the following binders may be used:
 70/100 penetration-grade bitumen;

 150/200 penetration-grade bitumen;
 MC-3000 cut-back bitumen;
 Spray-grade emulsion (65% or 70% of net bitumen).
(ii) Sand
The grading of the sand shall be in accordance with table 6303/14 shall be met.
(b) Construction
(i) Equipment
The following equipment shall be readily available on the site:
 Pneumatic-tyred rollers;
 A rotary broom;
 A drag broom;
 Mechanical aggregate spreaders.
(ii) Preparation of surface before application of seal

The surface of the layer that is to receive the sand seal shall be rolled and swept until a fine texture is
obtained. The layer shall then be primed in accordance with the provisions of Division 6100 or as
(iii) Application of sand seal

The primed surface shall be cleaned of all loose or deleterious material before the sand seal is
applied.
2
The binder shall be applied at 1.0 l/m net cold bitumen, and, immediately after the binder has been
3 2
applied, the aggregate shall be spread thereon at a rate of 0.007m /m and rolled with pneumatic-
tyred rollers. Where bitumen emulsions are used, the aggregate shall be applied only after the
emulsions have broken partially.
During the rolling process, any uneven application of sand shall be rectified with a light broom drag or
other suitable apparatus.
Where the sand seal is required to be applied in two applications, the second application of binder and
sand may be applied when the first application has cured sufficiently for it to take the traffic without
requiring brooming back of the sand. All loose sand and deleterious material shall be removed from
the surface and any damaged or defective areas rectified before the second application of binder and
sand. The surface may be opened to controlled traffic after the first application of emulsion and sand,
on approval by the Engineer
As wet sand is difficult to apply, the preparation of the sand should be done well ahead of the actual
construction to allow the sand to be fairly dry when it is applied. If the sand is not cleaned to the
Engineer's satisfaction by one screening and washing operation, it shall be washed again at no extra
payment.
Where required by the Engineer, the sand shall be pre-coated with an approved pre-coating agent,
3
applied at a rate of 7 l/m . No pre-coating will be allowed where emulsions are used as binders.

While the traffic is using the road, the sand shall be continuously broomed back onto the road until the
binder has cured sufficiently to retain the sand and until traffic does not damage the surface. The
sweeping-back process shall be done with a rotary broom or manually and may take as long as two
months before the surface finally settles down. Tenders shall be based on brooming back for up to five
(5) times.
6320 Graded Aggregate Seals

This Section covers the supply and application of graded aggregate surfacing seals (including Otta
Seals) for maintenance or new construction using a crushed or natural material, and cover seals made
of sand or crusher dust. Both single and double applications are covered.
(a) Materials
(i) Binders
150/200 penetration grade bitumen or MC 3000 cutback grade bitumen shall be used in warm
weather. In cold weather, when night temperatures are likely to fall below 10ºC, MC 800 cutback grade
bitumen may be used or alternatively 150/200 penetration grade bitumen may be cut back with
kerosene to the appropriate viscosity range, as directed by the Engineer. The specifications for the
various grades of bitumen as shown in sub-Clause 6303 (a) shall apply.
(ii) Kerosene for cutting back bitumen

Kerosene shall be used as the cutter where correction of viscosity is required or cutback bitumen is
made on site from penetration grade bitumen. Allowance shall be made for quantities between
0 and 25% by volume of the total quantity hot sprayed bitumen, as directed by the Engineer.
(iii) Anti-stripping agent

When an anti-stripping agent is required it shall be added to the bitumen immediately before the start
of spraying operations and shall be circulated for a minimum period of 30 minutes prior to spraying.
Anti-stripping agent that has been kept hot in the bitumen distributor for more than 5 hours shall be
considered stale, and a further dosage amounting to half of the originally specified shall be added.
(b) Aggregates for Otta Seals
(i) Grading
The grading curve for the Otta Seal shall fall smoothly within the envelope detailed in Table 6320/1.
The upper nominal size shall not be larger than 16 mm, if not otherwise directed by the Engineer to be
20 mm nominal size.
Table 6320/1: Grading for Otta Seals

BS Sieve size Percentage by mass passing
(mm) sieve (%)
19 100
16 80-100
13.2 52-100
9.5 36-98
6.7 20-80
4.75 10-70
2 0-48
1.18 0-38
0.425 0-25
0.075 0-10
(ii) Aggregate strength

The aggregate strength requirements tested according to test method SANS 3001-AG10 shall conform
to Table 6320/2.

Table 6320/2: Aggregate Strength for Otta Seals, General Requirements

Ten Per cent Fines 10% FACT
Value, (10% FACT dry) wet/dry ratio
Minimum 110 kN 75%
The aggregate strength for Otta Seals on roads with AADT less than 100 may be reduced to the
values shown in Table 6320/3 on approval of the Engineer.
Table 6320/3: Aggregate Strength for Otta Seals, AADT less than 100
Ten Per cent Fines 10% FACT
Value, (10% FACT dry) wet/dry ratio
Minimum 90 kN 60%
(iii) Flakiness Index

If crushed material is used the Flakiness Index shall be determined in accordance with SANS 3001-
AG4, and should not exceed 30.
(iv) Sand for cover seals

The materials used can be crusher dust, river sand or other natural sand and shall be non-plastic, free
from organic matter and lumps of clay. All the material shall pass the 6.3 mm sieve, unless otherwise
(c) Aggregates for Other Graded Seals

Alternative gradings for graded seals based on traffic levels in terms of AADT are shown in Table
Table 6320/4: Alternative Gradings for Graded Seals
BS Sieve Sizes Open Grading Medium Grading Dense Grading

(mm) (% Passing) (% Passing) (% Passing)
19 100 100 100
16 80 – 100 84 – 100 93 – 100
13.2 52 – 82 68 – 94 84 – 100
9.5 36 – 58 44 – 73 70 – 98
6.7 20 – 40 29 – 54 54 – 80
4.75 10 – 30 19 – 42 44 – 70
2.0 0–8 3 – 18 20 – 48
1.18 0–5 1 – 14 15 – 38
0.425 0–2 0–6 7 – 25
0.075 0–1 0–2 3 – 10
Recommended traffic
< 100 100 – 1000 > 1000
levels (AADT)
The other aggregate properties specified in sub-clauses 6320(b)(ii), (iii) and (iv) shall apply to
aggregates meeting the grading requirements of Table 6320/4.
(d) Construction and Aftercare

This sub-clause contains procedures for the construction of graded aggregate seals (including Otta
Seals), and sand cover seals. The operations listed below are part of normal construction procedures
for the seals and no additional payment will be made for any operation except that given under the
relevant Measurement and Payment item in Clause 6321.
 Granular road bases of non-calcareous materials do not normally require a prime, unless
otherwise directed by the Engineer. Calcrete road bases shall always be primed.

 The sealed surface shall receive not less than 30 passes of a pneumatic tyred roller on the
day of sealing. On the same day, the Engineer may direct one pass with a 12 tonne or heavier
tandem steel roller. During the following 2 days, the entire sealed area, including the
shoulders, shall receive a further minimum of 30 passes daily, unless otherwise approved by
the Engineer. A minimum of two pneumatic tyred rollers with a minimum weight of 12 tonne
shall be used for the rolling operations.
 The Engineer may direct even trafficking of the surfaced area and channelling of the traffic
may be required for certain periods and traffic cones or similar may be required.
 The road should be opened to traffic immediately after the sealing operations are completed,
but a maximum speed limit of 50 km/h should be enforced during the initial 2 - 3 weeks after
construction.
 Aggregate that has been dislodged by traffic during the immediate post construction period
shall be broomed back into the exposed areas during the first 2 - 3 weeks, as directed by the
Engineer.
 After 2 - 3 weeks of trafficking the excess aggregate shall be swept off the road surface and
the speed limitations can be lifted, unless otherwise directed by the Engineer. If natural gravel
is used with a fairly high content of fines, the period may be extended to 6 weeks or as
 A team shall be retained on site to deal with areas of bleeding if required. The team will be
required during the normal construction period as well as during the first hot season following
the completion of sealing operations. The Contractor’s attention is drawn to the fact that any
cost of mobilising and operating this team shall be included in the pay item rates.
 A minimum period of 12 weeks shall elapse between construction of the subsequent layers of
the surfacing, and during that period the road should receive as much heavy trafficking as
possible, unless otherwise directed by the Engineer.
 Prior to applying subsequent seals, the surfaced area shall be broomed free of dust and loose
stones or other foreign matter.
 The sand cover seal shall on the day of surfacing receive not less than 30 passes of a
pneumatic tyred roller with a minimum weight of 12 tonnes.
 Aggregate that has been dislodged by traffic during the immediate post construction period
shall be broomed back into the exposed areas during the first 2 - 3 weeks as directed by the
Engineer.
(i) Equipment
Plant and equipment required for the construction of Otta Seals shall be readily available on site.
(ii) Rates of application of material

 Binder for graded aggregate seals (including Otta Seals)
All spray rates refer to hot spray rates of binder including any cutters and shall fall within the range 1.5
and 2.0 l/m² per layer, for either single or double graded aggregate seals/Otta Seals applications. For
bidding purposes 1.7 l/m² should be used, however, the actual spray rate shall be established on site
for the approval of the Engineer. Absorbent aggregates with a water absorption of more than 2% shall
require an additional 0.3 to 0.5 l/m² (in total) for both layers, as directed by the Engineer.
 Binder for sand cover seal

All spray rates refer to hot spray rates of binder including any cutters and shall fall within the range 0.6
and 0.9 l/m² for sand cover seals. For bidding purposes 0.8 l/m² should be used, however the actual
spray rate shall be established on site for the approval of the Engineer.
 Anti-stripping agent
When required, the anti-stripping agent shall be mixed with the hot bitumen by 0.5% to 1.0% by weight
of bitumen as directed by the Engineer.
 Aggregate for graded aggregate seals (including Otta Seals)

The aggregate application rates for graded aggregate seals (including Otta Seals) shall be in the
range 0.013 to 0.020 m³/m².per layer. For bidding purposes a spread rate of 0.015 m³/m² per layer
should be used, however the actual spray rate shall be established on site for the approval of the
Engineer.
 Aggregate for sand cover seals

The application rates of crusher dust or sand shall fall within the range 0.010 to 0.012 m³/m² for sand
cover seals. For bidding purposes a spread rate of 0.011 m³/m² should be used, however the actual
spray rate shall be established on site for the approval of the Engineer.

Where, in the opinion of the Engineer, the corrective work executed in terms of clause 6310 is not for
the Contractor’s account, the Contractor will be remunerated at the applicable rates as determined by
the Engineer in accordance with the Contract.
Item 63.01 Single surface seal (indicate grade of aggregate and type of binder):
2
(a) Using 19.0 mm chippings .........................................................................square metre (m )
2
(b) Using 13.2 mm chippings .........................................................................square metre (m )
2
(c) Using 9.5 mm chippings............................................................................square metre (m )
2
(d) Using 6.7 mm chippings............................................................................square metre (m )
The unit of measurement shall be the square metre of completed and accepted surface treatment.
The tendered rates shall include full compensation, inter alia, for furnishing and transporting all
materials; marking the centreline or reference lines; spraying of binder; spreading of chippings; rolling;
removing of dust or deleterious material; supplying of water and spraying of haul roads and
construction roads; trimming the edges of the completed surface; and all other incidentals necessary
for completing the work as specified, except the application of a fog spray which shall be paid for
under item 63.09.
Item 63.02 Double surface seal using:

2
(a) 19.0 mm and 9.5 mm chippings (with specified binder) ..........................square metre (m )
{state grade of chippings and type of binder}

2
(b) 13.2 mm and 6.7 mm aggregate (with specified binder) ..........................square metre (m )
The tendered rate shall include full compensation for furnishing and transporting all materials; marking
the centre line; spraying of binders; spreading of aggregate; rolling; removing of dust or deleterious
material; supplying of water and spraying of haul roads and construction roads; trimming the edges of
the completed surface; and all other incidentals necessary for completing the work as specified.

Item 63.03 Triple bituminous surface treatment using:

2
(a) 26.5 mm, 13.2 mm and 6.7 mm chippings (with specified binder) .......... square metre (m )

2
(b) 19.0 mm, 9.5 mm and 6.7 mm aggregate (with specified binder) ............ square metre (m )
The tendered rate shall include full compensation for furnishing all materials, marking the centre line,
spraying of binders, spreading of chippings, rolling, removing of dust or deleterious material, supplying
of water and spraying of haul roads and construction roads, trimming the edges of the completed
surface and all other incidentals necessary for completing the work as specified.
Item 63.04 Single surface treatment and slurry (Cape Seal) using:
2
(a) 19.0 mm chippings {state type and grade of binder and aggregate}........ square metre (m )
2
(b) 13.2 mm chippings {state type and grade of binder and aggregate}........ square metre (m )
The unit of measurement for the complete bituminous single seal with aggregate and slurry shall be
the square metre.
The tendered rates shall include full compensation, for furnishing all materials, demarcating the
working area, spraying the binders, spreading the chippings, rolling, mixing and applying the slurry,
and all other incidentals necessary for completing the work as specified, including the watering of haul
and construction roads in and about the site.
Item 63.05 Sand Seal using:

2
(a) Sand seal {state type and grade of binder) .............................................. square metre (m )
2
(b) Grit seal {state type and grade of binder} ................................................. square metre (m )
The unit of measurement for the complete bituminous sand or grit seal with aggregate graded to Table
6303/14 shall be the square metre.
The tendered rates shall include full compensation, for furnishing and transporting all materials;
demarcating the working area; spraying the binders; applying and spreading the sand or grit; brooming
the sand back on to the paved surface (either mechanically or manually); rolling, and all other
incidentals necessary for completing the work as specified, including the watering of haul and
construction roads in and about the site.
Item 63.06 Graded aggregate seal or Otta Seal:

(a) First layer or single graded aggregate/Otta seal (grading of material and type and grade of
2
binder specified) ....................................................................................... square metre (m )
(b) Second layer for double graded aggregate/Otta seal (grading of material and type and grade
2
of binder specified) .................................................................................. .square metre (m )
The unit of measurement shall be the square metre of each layer of completed and accepted surface
treatment.
 Procurement of materials;
 Application of binders, spreading ,rolling, brooming back of dislodged material;
 Removing deleterious material;
 Supplying water and spraying of haul roads and construction roads;

 Trimming of edges of the completed surface;
 Final sweeping off of excess aggregate and all other incidentals for completing the work.
Item 63.07 Variations in the rate of application of Bituminous Binder:

a) 70/100 penetration-grade bitumen ............................................................................. litre (ℓ)
b) 150/200 penetration-grade bitumen ........................................................................... litre (ℓ)
c) 65% cationic spray grade emulsion ............................................................................ litre (ℓ)
d) 60% cationic spray grade emulsion ............................................................................ litre (ℓ)
e) 60% anionic spray grade emulsion............................................................................. litre (ℓ)
f) Pre-coating fluid .......................................................................................................... litre (ℓ)
g) MC-3000 cutback bitumen .......................................................................................... litre (ℓ)
h) Modified binders as classified in Table 6303/4 ........................................................... litre (ℓ)
The unit of measurement for bituminous binder in respect of an increase or a decrease in the specified
rates of application of specific binders shall be the litre measured at spraying temperature (the
Contractor must note that the nominal rates of application are specified in net cold bitumen).
Payment for variations shall be made as specified in the Conditions of Contract.
Item 63.08 Variations in the rate of application of Chippings:

3
(a) 26.5 mm chippings ...................................................................................... cubic metre (m )
3
(b) 19.0 mm chippings ...................................................................................... cubic metre (m )
3
(b) 13.2 mm chippings ...................................................................................... cubic metre (m )
3
(c) 9.5 mm chippings ........................................................................................ cubic metre (m )
3
(d) 6.7 mm chippings ........................................................................................ cubic metre (m )
The unit of measurement for chippings in respect of an increase or a decrease in the specified rates of
application shall be the cubic metre of chippings.
Item 63.09 Application of fog spray:

(a) 60% spray grade emulsion (indicate type)................................................................. litre (ℓ)
(b) 30% spray grade emulsion (indicate type) ................................................................ litre (ℓ)
The unit of measurement shall be the litre, measured at spraying temperature. The tendered rate shall
include full compensation for furnishing the material and applying the fog spray as specified.
3
Item 63.10 Pre-coating chippings (as specified) ............................................... cubic metre (m )
(state type of pre-coating fluid)
The unit of measurement for the pre-coating of chippings shall be the cubic metre of chippings so
treated determined from the usage of the chippings at the specified chipping application rate.

The tendered rate shall include full compensation for furnishing the equipment and materials and pre-
coating the chippings as specified, including the handling, stockpiling and protecting the stockpiles
against inclement weather.
Item 63.11 Addition of wetting agent {state type of wetting agent}

(a) Providing and supplying .............................................................................. prime cost sum
(b) Handling, applying, profit and all other costs ......................... percentage of prime cost sum
The prime cost sum shall be paid for in terms of the general conditions of contract for providing and
supplying an approved wetting agent to the pre-coating fluid as specified or as directed by the
Engineer.
The tendered percentage of the prime cost sum shall include full compensation for handling the
material, storing and introducing it into the mix, including any equipment required, and for all other
costs and profit.
Item 63.12 Aggregate for blinding

3
(a) Natural sand ...............................................................................................cubic metre (m )
3
(b) Crusher sand ...............................................................................................cubic metre (m )
The unit of measurement shall be the cubic metre of sand measured in the hauling vehicles.
The tendered rate shall include full compensation for providing the material and applying the blinding
coat complete as specified, and, should it be required, stockpiling the sand at an approved locality.
Item 63.13 Extra over item for surface treatment of areas inaccessible to mechanical
equipment:
(a) For Single Seal ......................................................................................... square metre (m²)
(b) For Double Seals ...................................................................................... square metre (m²)
(c) For Triple Seals ........................................................................................ square metre (m²)
(d) For Cape Seals ......................................................................................... square metre (m²)
(e) For Sand Seals ......................................................................................... square metre (m²)
(f) For Single Graded Aggregate/Otta Seals ................................................. square metre (m²)
(g) For Double Graded Aggregate/Otta Seals ............................................... square metre (m²)
The unit of measurement shall be the square metre of completed treatment.
The tendered rate per square metre of treatment shall include full compensation for procuring,
furnishing all materials; and for all labour, plant, transport and other incidentals necessary for
completing the work as specified, including application of prime, tack coat and slurry as required or as
Item 63.14 Resurfacing at bridge joints:

(a) Where the existing surface is not removed ........................................................... metre (m)
(b) Where the existing surface is removed ................................................................. metre (m)
The unit of measurement shall be the metre of bridge joint situated in the surface to be resurfaced,
and which has been protected in accordance with the specifications to the satisfaction of the Engineer.
The tendered rate shall include full compensation for protecting the bridge joints against damage,
blockage and soiling until the resurfacing has been completed including the procuring, placing and
removing of all covering material, and all other incidentals required for executing the work in
accordance with the specifications.
The tendered rate for sub-item (b) shall include full compensation for cutting back in the existing
surfacing, treating and backfilling it, and disposing of excavated material, all as specified and to the
Satisfaction of the Engineer.
Item 63.15 Correction for bleeding using:

(a) Chippings:
3
(i) 13.2 mm chippings ......................................................................... cubic metre (m )
3
(ii) 9.5 mm chippings ........................................................................... cubic metre (m )
3
(iii) 6.7 mm chippings ........................................................................... cubic metre (m )
3
(b) Pre-coating of chippings ............................................................................. cubic metre (m )
2
(c) Treatment of surface .................................................................................square metre (m )
The unit of measurement for correction of bleeding shall be the cubic metre of chippings applied. The
tendered rate shall include full compensation for procuring, furnishing and transporting the materials;
and, if required, for stockpiling the material at selected sites indicated by the Engineer.
The unit of measurement for pre-coating of chippings shall be the cubic metre of material pre-coated.
The tendered rate shall include full compensation for pre-coating the material as specified, for
procuring and furnishing the pre-coating material regardless of the type of pre-coating material used,
and for the handling, loading, transporting and offloading of all materials.
The unit of measurement for treatment of the surface shall be the square metre of surface treated. The
tendered rate shall include full compensation for all labour, plant, and equipment and transport
required treating the surfaces as specified including maintenance and all incidentals necessary for the
completion of the work.
Item 63.16 Supplying and mixing of kerosene for cutback bitumen .......................... litre (ℓ)
The unit of measurement of kerosene used to cut back penetration-grade bitumen shall be the litre,
measured at ambient temperature.
The tendered rate shall include full compensation for procuring and furnishing the kerosene and
mixing it with the bitumen and spraying, including all incidentals.
3
Item 63.17 Variations in the rate of application of slurry ................................. cubic metre (m )
The unit of measurement for slurry variations in respect of an increase or a decrease in the specified
rates of application shall be the cubic metre of saturated fine aggregate.
Every load of fine aggregate used for the slurry shall be struck off with a straight-edge at the stockpile,
and the volume shall then be measured and corrected for bulking. The following method shall be used
for calculating the corrected volume of fine aggregate when determining the application rate of the
slurry:
The volume of a truck hopper filled with fine aggregate shall be carefully measured in cubic metres
(say A cubic metres).
A representative sample of aggregate shall be obtained from the conveyor belt feeding the mixer.
1000 ml of the sample shall be placed in a plastic measuring cylinder and dropped ten times through a
height of 50 mm onto a wooden table, after which the volume of aggregate in the cylinder shall then be
measured in millilitres (say B millilitres).
The sample in the cylinder shall then be saturated with water and water shall be added until it covers
the aggregate by 50 mm. The mixture shall be shaken well, and the cylinder containing the aggregate
and water placed on a horizontal surface allowing the aggregate to settle until the liquid above the
aggregate clears sufficiently for a reading to be taken of the volume of the saturated aggregate, in
millilitres (say C millilitres).
The saturated volume of the aggregate in the hopper of the truck shall be calculated from the following
formula, and payment for the slurry application variations shall be made in accordance with this
formula:
True (saturated) volume carried by the truck hopper = A x (1-0.72(B-C)/C)
Item 63.18 Variations in Active Filler content for Slurry Seal ....................................... tonne (t)
The unit of measurement in respect of increases or decreases in the active filler content from that
specified in the normal mix for tender purposes shall be the tonne. No payment shall be made for inert
filler added by the Contractor.
Item 63.19 Anti-stripping agent .......................................................................................... litre (ℓ)

The unit of measurement for the supply of an anti-stripping agent shall be the litre.
The tendered rate shall include full compensation for procuring, furnishing, transporting and mixing the
anti-stripping agent with the hot bitumen.

Division 6400: Asphalt Road Base and Surfacings
6401 Scope
This section covers:
 All work in connection with the construction of hot, premixed, bituminous materials for bases,
binder courses and surfacing. It includes the procuring and furnishing of aggregate and
bituminous binder, mixing at a central mixing plant, spreading and compaction of the mixture,
as specified for the construction of:
o Continuously graded asphalt base/binder and wearing course;
o Gap-graded asphalt base and wearing course;
o Open-graded asphalt surfacing;
o Stone-mastic asphalt surfacing;
o Dense Bitumen Macadam for base and wearing course; and
o The widening of asphalt bases and surfacing;
 Placing asphalt in restricted areas;
 Placing asphalt reinforcing where specified.
 The recycling of asphalt by reprocessing recovered materials, adding fresh aggregate,
bituminous binders and other agents for obtaining an asphalt mix which will comply with the
specified requirements, and placing the recycled material. The provisions of Division 6400
shall apply throughout to recycled asphalt, except where explicitly specified in the Particular
Specifications.
 The construction of asphalt surfacing on bridge decks where shown on the Drawings or
ordered by the Engineer.
6402 Materials
(a) General
All materials shall be handled and stockpiled in a manner that will prevent contamination, segregation
or damage. Cement and lime shall be used in the order in which it has been received on site.
The Contractor shall, as often as necessary, test and control the materials produced directly, or the
materials received from suppliers, to ensure that the materials comply with the specified requirements.
(b) Bituminous binders

The type and grade of bituminous binder to be used in each case shall be as specified hereinafter or
in the Particular Specifications.
The provision of sub clause 6303(a)(i) shall apply to the selection of a suitable binder for asphalt road
base and surfacings.
(i) Penetration Grade Bitumen (Based on SANS 4001-BT1)

The specification for penetration grade bitumen used for hot mix asphalt shall comply with the
requirements of Table 6402/1.
The harder grades of 10/20 and 15/20 shall only be used for high modulus asphalt, as a base material,
unless otherwise instructed by the Engineer.

Table 6402/1: Specifications for Penetration Grade Bitumens
Penetration Grade
Property 10/20 15/25 35/50 50/70 Test Method
Requirement Limits
Penetration @ 25ºC (100g/5s) ,
10 – 20 15 – 25 35 – 50 50 – 70 EN 1426
0.1mm
Softening Point, ºC 58 – 78 55 – 71 49 – 59 46 – 56 ASTM D361
Minimum viscosity @ 60ºC, mPa.s 700 550 220 120 ASTM D44022
Viscosity @ 135ºC, mPa.s ≥750 ≥650 270 – 700 220 – 500 ASTM D44022
Flash point, ºC, min 245 235 240 230 ASTM D92
Mass Change, % max - 0.5 0.3 0.3 ASTM D2872
Performance
Viscosity @ 60ºC, %
when - - 300 300 ASTM D44022
of original max
subjected to
Softening Point, ºC
rolling thin - 57 52 48 ASTM D361
min
film oven
Increase in Softening
test, 10 8 7 7 ASTM D361
Point, ºC max
ASTM
D2872 Retained Penetration,
- 55 60 55 EN 1426
% of original min
3
Spot test, % xylene max - - 30 30 AASHTO T102
1
Using shouldered rings in the test
2
Recommended apparatus is the RV viscometer, using SC4dles with the Thermosel system
3
Actual values to be reported in 5-unit intervals
rd
(ii) Modified Binders (based on TG1, 3 edition, 2014 from SABITA)
Modified bituminous binders shall be divided into the following two broad compositional groups:
 Homogenous Binders;
 Non-homogenous Binders
The generic binders classified in Table 6402/2 are suitable for pre-mixed asphalt surfacings.
Table 6402/2: Classification for Modified Binders for Hot Mix Asphalts
Modified Binder Class Compositional Group Application

A-E1 Homogenous Hot mix asphalt - elastomer modified
A-E2 Homogenous Hot mix asphalt - elastomer modified
1
A-P1 Homogenous Hot mix asphalt - plastomer modified
A-R1 Non-homogenous Hot mix asphalt - rubber modified
1
Some of the modifiers in this generic class are capable of imparting fuel resistant properties
The properties of the modified binder classes shown in Table 6402/2 are specified in Tables 6402/3
and 6402/4.
Table 6402/3: Specification for Polymer Modified Binders for Hot Mix Asphalt
Test method Class
Property Unit (as provided in TG 1 unless
A-E1 A-E2 A-P1
Before Ageing
1
Softening Point ºC MB-17 55 - 65 65 - 85 63 – 73
Elastic recovery @ 15ºC % MB-4 > 50 > 60 30 – 50
Dynamic Viscosity @ 165ºC Pa.s MB-18 ≤ 0.6 ≤ 0.6 ≤ 0.55
Storage Stability @ 160ºC ºC MB-6 ≤5 ≤5 ≤5
Flash Point ºC ASTM D92 ≥ 230 ≥ 230 ≥ 230
After Ageing with Rolling Thin Film Oven (RTFOT) to ASTM D2872
Mass Change % MB-3 ≤ 1.0 ≤ 1.0 ≤ 1.0
Softening Point ºC MB-17 ≥ 53 ≥ 63 ≥ 61
Elastic Recovery @ 15ºC % MB-4 > 40 > 50 -
1
The prescribed test method is based on not using stirrers although it has been reported that the use of stirrers has shown no
difference in test results. For refereeing purposes, no stirrer should be used.

Table 6402/4: Specifications for Bitumen Rubber for Asphalt
Test method Class

Property Unit
unless indicated A-R1
otherwise)
Softening Point ºC MB-17 55 – 65
Dynamic Viscosity @ 190ºC dPa.s MB-13 20 – 50
5 mins > 80
Compression
1 hour % MB-11 > 70
Recovery
24 hours n/a
Resilience @ 25 ºC % MB-10 13 – 40
Flow Mm MB-12 10 – 50
(iii) Requirement for Rubber Crumb for modified bitumens (based on the prevailing version of TG1
from SABITA)
Table 6303/8 shows the requirements for rubber crumbs for modifying bitumens.
The rubber crumb shall be obtained by processing and recycling pneumatic tyres. Crumbs produced
by cryogenic-mechanical techniques shall not be permitted. The crumb shall be pulverised, free of
fabric, steel cords and other contaminants. A maximum of 4% by mass of fine particle size calcium
carbonate or talc, may be added to the rubber crumbs to prevent the rubber particles from sticking
together. At the time of use the crumbs shall be free flowing and dry.
(c) Aggregate Properties

Aggregate is the major component in HMA and the quality and physical properties of the aggregates
has a large influence on mix performance. The qualities required of aggregates are described in terms
of shape, hardness, durability, cleanliness, bitumen affinity and porosity. In addition to these
properties, the micro texture of the aggregate particles will also strongly influence the performance of a
compacted HMA layer. Smooth-surfaced river gravel, even partly crushed, may not generate as much
internal friction as a totally crushed aggregate from particles having a coarse micro texture.
Coarse and fine aggregate shall be clean and free from decomposed materials, vegetable matter and
other deleterious substances.
The coarse aggregates used for making HMA should be produced by crushing sound, unweathered
rock or natural gravel. Gravel should be crushed to produce at least two fractured faces on each
particle.
The aggregate shall be;
 Angular and not excessively flaky, to provide good mechanical interlock;

 Clean and free of clay and organic material;
 Strong enough to resist crushing during mixing and laying as well as in service;
 Resistant to abrasion and polishing when exposed to traffic;
 Non-absorptive - highly absorptive aggregates are wasteful of bitumen and also give rise to
problems in mix design; and
 Have good affinity with bitumen - hydrophilic aggregates may be acceptable only where
protection from water can be guaranteed or a suitable adhesion agent is used.
Filler (material finer than 0.075 mm) can be crushed rock fines, Portland cement or hydrated lime.
Portland cement or hydrated lime is often added to natural filler (1 - 2 per cent by mass of total mix) to
improve the adhesion of the bitumen to the aggregate.
The required properties for aggregates are given in Table 6402/5.

The Polished Stone Value (PSV) of aggregates shall not be less than the values shown in
Table 6303/13 when used for surfacings.
In addition, for asphalt road bases, at least 50% by mass of the individual fractions retained on each of
the standard sieves with a square mesh size of 4.75 mm and larger shall have at least one fractured
face and for wearing courses at least 95% of all particles shall have at least three fractured faces.
Enhanced specifications for rolled-in chippings and for open graded surfacings are shown in
Table 6402/6.

Table 6402/5: Properties for Asphalt Aggregates
Properties
Property Test Test Method
Wearing course Binder course
6
Sand equivalent: for < 1.5 x 10 ESA > 35
AASHTO T176-86
< 4.75mm fraction 6
>1.5 x 10 ESA > 40
Cleanliness
Material passing 0.425mm Plasticity Index <4
sieve
AASHTO T-90
Linear shrinkage % <2
Particle shape Flakiness Index < 35 BS 812, Part 105 (1990)
10% FACT (dry) kN > 160 BS 812, Part 3 (1985)
Strength 10% FACT – wet/dry ratio > 75% BS 812, Part 3 (1985)
Los Angeles Abrasion (LAA) < 30 < 35 ASTM C131 and C535
Abrasion Aggregate Abrasion Value < 250 cv/lane/day < 16 -

BS 812, Part 3 (1985)
(AAV) > 3250 cv/lane/day < 12 -
Polishing Polished Stone Value (see Table 6303/13) - BS 812, Part 3 (1985)
Water absorption Water absorption
6
<2 BS 812, Part 2 (1975)
Coarse < 10
Soundness Sodium Sulphate Test:
Fine < 16
AASHTO T104-99
(5 cycles, % loss) Coarse < 15
Magnesium Sulphate Test:
Fine < 20
Immersion Mechanical Test: Index of retained Marshall stability > 75

D Whiteoak (1990)
Bitumen affinity
Static Immersion Test > 95% coating retained AASHTO T283
Retained Indirect Tensile strength > 79% (at 7%VIM)

Table 6402/6: Enhanced Specifications for Rolled-in Chippings, Open-Graded Surfacings and
Stone Mastic Surfacings
Rolled in Open-graded Stone Mastic

Property
Chippings Surfacings Surfacings
10% FACT Dry > 210 > 210 > 210
(13.2mm and
Wet/Dry
9.5mm > 75% > 75% > 75%
ratio
fractions)
Flakiness Index (>13 mm) <20 <30 <30
6403 Mix Design

The Contractor shall, by conducting the necessary tests, satisfy himself that he will be able to produce
a mixture meeting the design requirements specified hereinafter using the aggregate and bituminous
binder proposed for supply, within the grading limits specified.
The design of an HMA mix involves the following iterative process;
 Establish candidate mixes with satisfactory volumetric composition;

 Testing to confirm that the compacted mix has the required properties for the expected traffic;
and, if necessary,
 Adjust the mix composition and re-test until the design requirements are satisfied.
The mix design for asphalt surfacing materials shall be based on the recommendations given in the
Asphalt Institute Manual Series, MS-2, and carried out using the Marshall Test procedure. This
method employs impact compaction with the Marshall hammer to produce briquettes of different
compositions. The briquettes are then tested to ensure that the mix criteria are appropriate for the
design traffic. An outline of the method is described in Appendix C of the Pavement Design Manual,
Volume 1 Flexible Pavements.
Irrespective of the particle size distribution that is chosen, a blend of aggregate particles suitable for
asphalt surfacings must produce a mix which shall;
 Have sufficient Void in the Mineral Aggregate (VMA) to accommodate enough bitumen to
make it workable during construction;
 Be durable in service; and
 Retain a minimum of 3 per cent Voids in the Mix (VIM) after secondary compaction by traffic.
An aggregate blend for hot mix asphalt (HMA) shall be characterised by;
 The nominal maximum stone size – defined as one sieve size larger than the first sieve to
retain more than ten per cent; and
 The maximum stone size - defined as one sieve size larger than the nominal maximum size.
The nominal maximum stone size determines the minimum VMA required in the aggregate blend.
Asphalt surfacings thicker than about 70mm are laid as two layers and the relationship between the
thickness of a layer and the maximum stone size largely determines the particle size distribution that
will be used. To achieve good compaction the layer thickness shall be between 2.5 times the
maximum stone size for fine mixes and 4 times the maximum stone size for mixes with a high content
of coarse aggregates such as those normally recommended for severe traffic loading.
The Contractor shall be fully aware that the performance of HMA is very sensitive to the particle size
distribution (grading) of the granular material. The maximum density achieved in service must be such
that there is enough space to accommodate the design bitumen content and to provide enough

remaining air voids to prevent overfilling with bitumen and rapid shear failure under heavy traffic. At the
same time the air voids must be as low as possible to minimise bitumen oxidation, ageing and
subsequent cracking and failure.
Unfortunately, there is no simple way of ensuring this merely from the grading. This is because the
packing of aggregate particles depends on other properties that cannot be adequately specified for
construction purposes such as shape and surface texture of each and every fraction.
As a consequence, the nature of HMA design is such that precise proportions of the constituents of a
mix can only be determined during the mix design process; hence the proportions used in the
tendering process will almost certainly change. The specified grading envelopes are merely an initial
guide. Trial and error are vital to obtain the final design grading. This is the ‘job mix’ formula.
Once the job mix design has been completed satisfactorily, the tolerances on the mix proportions are
very close and necessary for the manufacture of a strong and durable mix. The tolerances are shown
in Table 6403/1 and deviation limits from the agreed target grading are shown in Table 6403/2. Any
approved variation on a nominal mix in the bitumen content or active filler content shall be the subject
of an adjustment in payment for binder or active filler variations as described in Clause 6416.
Table 6403/1: Tolerances for the Manufacture of Asphalt Concrete
Tolerances for mix constituents
Passing sieve Permitted Bitumen content (%)

size range
(mm) (%) Wearing Binder
course course
>12.5 ±8
9.5 ±7
4.75 ±7
±0.3 ±0.5
2.36 ±6
300 microns ±5
75 microns ±3
Table 6403/2: Deviation from approved target grading
Material passing sieve size Permissible deviation from approved

(mm) target grading (%)
26.5 ± 5.0
19.0 ± 5.0
13.2 ± 5.0
9.5 ± 5.0
6.7 ± 5.0
4.75 ± 4.0
2.36 ± 4.0
1.18 ± 4.0
0.60 ± 4.0
0.30 ± 3.0
0.15 ± 2.0
0.075 ± 1.0 *
* When statistical methods are applied the permissible deviation for the 0.075 mm fraction is ±2.0%.
A more comprehensive design method, the Superpave method of design, is described in the Asphalt
Institute Superpave Series No.1 and No.2, and Appendix D of the Pavement Design Manual, Volume 1

Flexible Pavements. This procedure uses a gyratory compactor for sample preparation which
produces incremental steps of compactive effort. The levels of compaction used in the design are
related to the expected pavement temperature and traffic loading. For traffic loading up to 1 million
esa, mix composition is essentially based on the principles given in MS-2 using the procedure
described in sub-clause 6403(a). For design traffic between 1 and 10 million esa an intermediate level
of performance testing is called for and detailed analysis is required for traffic loading in excess of 10
million esa.
Note - a performance-based design using Superpave test equipment or similar can take as long as one month to
complete and is not recommended for site laboratories. Marshall design can be carried out in site laboratories on
most major projects and therefore, the Marshall procedure shall remain the principle method of mix design and
quality control for asphalt mixes unless indicated in the Particular Specifications. The use of performance tests of
the types described in Appendix F of the Pavement Design Manual, Volume 1 Flexible Pavements shall be
undertaken on instruction by the Engineer.
(a) Mix Proportions

The grading of the combined aggregate (meeting the requirements of 6402(c)), including any filler
added in an approved working mix; and the binder content shall be within the limits stated in Tables
6403/3 to 6403/9 for the various mixes. The grading approved by the Engineer shall be designated as
the target grading.
The mean grading of each lot of the working mix (minimum of 6 tests per lot), determined from
samples obtained in a stratified random sampling procedure, shall conform to the approved target
grading within the tolerances specified in Tables 6403/1 and 6403/2.
(i) Continuously graded Asphalt Concrete (AC) wearing courses

The particle size distributions for continuously graded asphalt concrete (AC) or hot mix asphalt (HMA)
wearing courses are shown in Table 6403/3.
Table 6403/3: Particle Size Distributions for AC Wearing Courses (Asphalt Institute, 1994)
Nominal maximum stone size (mm)

Sieve size
Percentage passing sieve
(mm)
19 12.5 9.5
25 100
19 90 – 100 100
12.5 - 90 – 100 100
9.5 56 – 80 90 – 100
4.75 35 – 65 44 – 74 55 – 85
2.36 23 – 49 28 – 58 32 – 67
0.300 5 – 19 5 – 21 7 – 23
0.075 2–8 2 –10 2 – 10
Bitumen content (%) 4 - 10 4 - 11 5 - 12
Mix manufacture shall be carried out on the basis of blending materials by mass while mix design shall
be carried out on a volumetric basis. If the specific gravity of the individual unblended aggregates
differs by more than 0.2 then the specified masses of the different aggregates in the blend shall be
adjusted so that the volumetric properties of the plant mix are correct.

(ii) Continuously-graded AC binder courses and road bases

Particle size distributions suitable for AC binder course and road base material are shown in
Tables 6403/4. The Marshall test method cannot be used to design mixes with aggregate larger than
25mm; hence, the design of coarse binder courses and road bases shall rely on empirical knowledge.
Table 6403/4: Particle Size Distributions for AC Bases and Binder Courses (Asphalt Institute,
1994)
Layer Base Binder course

Nominal maximum size (mm)
Sieve size
Per cent passing sieve size
(mm)
37.5 25
50 100
37.5 90 – 100 100
25 – 90 – 100
19 56 – 80 –
12.5 – 56 – 80
4.75 23 – 53 29 – 59
2.36 15 – 41 19 – 45
0.300 4 – 16 5 – 17
0.075 0–6 1-7
Typical bitumen content (%) 3-8 3-9
(iii) Dense Bitumen Macadam (DBM)

Particle size distributions recommended for DBM wearing courses; and for binder course and road
base layers, are shown in Tables 6403/5 and 6403/6.
Table 6403/5: Particle Size Distributions for DBM Wearing Courses
UK nomenclature for size (mm)

Sieve size
Percentage passing sieve size
(mm)
14 10
20 100
14 95 – 100 100
10 70 – 90 95 – 100
6.3 45 – 65 55 – 75
3.35 30 – 45 30 – 45
1.18 15 – 30 15 – 30
0.075 3–8 3–8
Typical bitumen content (%) 4.9 5.2

Table 6403/6: Particle Size Distributions for DBM Binder Course and Base Layers
Binder course Base

Sieve size UK nomenclature for size (mm)
(mm) Percentage passing sieve size
20 40 28
50 – 100 –
37.5 – 95 – 100 100
28 100 70 – 94 90 – 100
20 95 – 100 – 71 – 95
14 65 – 85 56 – 76 58 – 82
10 52 – 72 – –
6.3 39 – 55 44 – 60 44 – 60
3.35 32 – 46 32 – 46 32 – 46
0.300 7 – 21 7 – 21 7 – 21
0.075 2–9 2–9 2–9
Typical bitumen content 4.7% 3.5% 4.0%
(iv) Gap-graded Mixes

A gap-graded mix relies for its properties primarily on the mortar of bitumen, filler (<0.075 mm) and
fine aggregate (0.075 - 2.36 mm). The coarse aggregate (>2.36 mm) acts as an extender but its
influence on stability and density increases as the proportion of coarse aggregate in the mix increases
particularly at the higher percentages. If the coarse aggregate content is less than about 40%, pre-
coated chippings shall be rolled into the surface to provide texture for good skid resistance where
necessary.
Gap-graded mixes have often been developed to recipe specifications but can also be designed using
the Marshall Test so that the physical characteristics of the fine aggregate can be taken into account
(British Standard 594 (1985)).
In tropical climates, wearing courses shall have target filler-to-binder ratios in the range 0.8 - 1.0. The
composition of suitable gap-graded mixes is shown in Table 6403/7.
Note: Mixes made with natural sand are more tolerant of proportioning errors than asphaltic concrete and are
easier to compact. Although the air voids tend to be slightly higher than asphaltic concrete, they are
discontinuous and the mixes are impermeable.

Table 6403/7: Particle size distribution for Gap-graded mixes
Mix designation WC1 WC2 BC1 BC1

(1,2)
Layer Wearing Course Basecourse
BS test sieve (mm) Percentage by mass of total aggregate passing test sieve
28 - - - 100
20 100 100 100 90 - 100
14 90 - 100 90 - 100 90 - 100 65 - 100
10 50 - 85 50 - 85 65 - 100 35 - 75
2.36 50 - 62 50 - 62 35 - 55 35 - 55
0.6 35 - 62 20 - 40 15 - 35 15 - 55
0.212 10 - 40 10 - 25 5 - 30 5 - 30
0.075 6 - 10 6 - 10 2-9 2-9
Type of fines Natural sand Crushed rock Sand or crushed rock
Bitumen (pen) 35/50 or 50/70 50/70 35/50 or 50/70
Nominal thickness of
50 40-65 50-80
layers (mm)
Bitumen content (per Minimum target value 6.5 + 0.6 (with crushed
cent by mass of total 6.3 + 0.5
(3) rock)
mix) 6.3 + 0.6 (with gravel)
Notes:
1
The preferred target for coarse aggregate is 50 per cent.
2
For WC1 a maximum of 12 per cent should be retained between the 0.6 mm and 2.36 mm sieves.
3
With 50 per cent coarse aggregate (see BS594).
(v) Stone Mastic Asphalt (SMA)

The primary characteristic of properly designed SMAs is their good resistance to permanent
deformation. They also have a relatively high durability and generally also better wet-weather skid
resistance and noise reduction characteristics than densely graded mixes. SMA mixes rely on a stone
skeleton to provide stability. This skeleton is provided by a coarse, gap-graded aggregate structure,
which is filled with a mastic consisting of binder, filler and fibres.
A key to the successful design of SMA mixes is the selection of a proper gradation, coupled with the
selection of a correct mastic content to ensure that stone-to-stone contact is maintained. By
comparison with densely graded mixes, SMA has a relatively high binder and filler content. Fibres are
normally added to the mix to prevent drain-down of the binder. It is thus not economical to use SMA
mixes in a structural layer. In practice, this means that the thickness of an SMA layer is generally
limited to 40 mm or less. Design considerations are given in the Sabita Manual 24 User Guide to the
design of Hot Mix Asphalt. The particle size distribution is shown in Table 6403/8.

Table 6403/8: Particle size distribution for Stone Mastic Asphalt surfacings
Aggregate size 13.2 mm 9.5 mm 6.7 mm

Sieve size (mm) Percentage passing by mass
13.2 100 - -
9.5 67 – 90 100 -
6.7 41 – 65 50 – 80 100
4.75 30 – 50 30 – 55 80 – 100
2.36 21 – 32 22 – 32 34 – 44
1.18 17 – 27 17 – 27 24 – 34
0.600 14 – 24 14 – 23 18 – 30
0.300 11 – 23 11 – 22 13 – 25
0.150 9 – 17 9 – 19 9 – 19
0.075 7 - 12 7 - 12 7 – 12
Binder 5 - 7%
Binder stabiliser (cellulose
0.5 0.5 0.5
fibres)
(vi) Open-graded mixes

Open-graded asphalt mixes (also called porous asphalt) are used primarily as a surfacing layer to
improve skid resistance and visibility in wet weather; and also to reduce noise pollution. The void
content for open-graded mixes shall be typically of the order of 20 per cent, with most voids being
interconnected. Open-graded mixes rely on a stone skeleton for stability, and generally have good
resistance to permanent deformation provided that a high quality aggregate is used. Because of their
high permeability, open-graded mixes shall be underlain by an impervious layer.
The main problem with open graded mixes is their durability. Their open nature provides a ready path
for oxygen and relatively rapid ageing of the binder occurs leading to cracking.
Particle size distributions are shown in Table 6403/9 and their design is described in the Sabita Manual
17 “The design and use of porous asphalt mixes”.

Table 6403/9: Particle size distribution for open-graded surfacings
Nominal size 13.2 mm

9.5 mm
Type Type 1 Type 2 Type 3
Sieve size (mm) Fraction passing by mass (%)
19.0 100 100 100 100 - -
13.2 90 – 100 90 – 100 90 – 100 70 – 100 100 -
9.5 30 – 50 30 – 50 30 – 50 50 – 80 50 – 70 100
4.75 10 – 20 10 – 20 10 – 20 15 – 30 20 – 30 10 – 25
2.36 8 – 14 8 – 14 8 – 14 10 –22 5 – 15 5 – 15
0.600 - - - 6 – 13 - -
0.300 - - - - 3–8 -
0.075 2-6 2-6 2-6 3–6 2–5 2-6
Nominal mix proportions by mass (%)
Penetration Polymer Bitumen- Bitumen- Bitumen- As for type 1
Binder type
Grade Modified Rubber Rubber Rubber
Aggregate 94.5 94.0 93.5 93.5 93.5 As for type 1
Nominal bitumen 4.5 5.0 5.5 5.5 5.5 As for type 1
(mass %)
Active filler 1.0
(mass%)
The selected target grading for open-graded asphalt mixes shall be such that in the case of medium
open-graded asphalt mixes of type 2 and 3, the void content of the compacted mix shall be between
18% and 22%, while for all other types, the void-content shall be between 20% and 25%.
(vii) Rolled-in chippings

Rolled-in chippings for asphalt surfacing mixes shall comply with the grading requirements of
Table 6403/10.
Table 6403/10: Particle size distribution for rolled-in chippings
Nominal size 19.0 mm 13.2 mm

Sieve size (mm) Fraction passing by mass (%)
19.0 100 -
13.2 0 – 20 100
9.5 0–5 0 – 20
6.7 0–1 0–5
0.425 0 – 0.5 0 – 0.5
(viii) Filler
If the grading of the combined aggregates for asphalt surfacing mixes shows a deficiency in fines, an
approved filler may be used to improve the grading. Filler may consist of active filler as defined
hereinafter or of inert material such as rock dust having the required grading necessary to improve the
grading of the combined aggregates. In no instance shall more than 2% by mass of active filler be
used in asphalt mixes. Inert filler such as rock dust used to improve grading shall not be subject to this
limitation.

The Engineer may order the use of any active filler to improve the adhesion properties of the
aggregate. Active filler shall consist of milled blast furnace slag, hydrated lime, ordinary Portland
cement, Portland blast furnace cement, fly-ash, or a mixture of any of the above materials. Individual
materials shall comply with the requirements of the relevant specifications for such material. Active
filler shall have at least 70% by mass passing the 0.075 mm sieve and a bulk density in toluene
between 0.5 and 0.9 g/m l. The voids in dry compacted filler shall be between 0.3% and 0.5% when
tested in accordance with BS 812.
(b) Mix Design Specifications for Conventional Asphalts and Macadams

Mix designs carried out as described in the Pavement Design Manual, Volume 1, Flexible Pavements
based on the Asphalt Institute Manual MS-2, using materials complying with the specifications herein
shall meet the following design parameters.
(i) Mix design for continuously graded wearing courses

Continuously graded AC wearing courses tend to be sensitive to variations in composition. Hence the
Contractor and the Engineer shall exercise a high level of quality control during laboratory design,
manufacture, compliance testing and construction. Table 6403/11 shows the target Voids in Mix (VIM)
for a durable and stable mix. Expected problems with mixes having VIMs outside the 3 – 5 % limits are
also shown in Table 6403/11.
Table 6403/11: Critical Values of VIM (after Secondary Compaction)
VIM in a wearing
course material Effect
(per cent)
Extremely permeable to air and water. Oxidation of the bitumen very
>8
rapid in hot climates
>5 Increasingly permeable to air and prone to oxidation of the bitumen
4 or 5 Target for design
3-5 For a durable and stable mix
<3 Prone to plastic deformation under heavy loading
In order to achieve a balance of mix properties it is important that the aggregate structure of a hot mix
asphalt (HMA) has sufficient VMA (Voids in Mineral Aggregate). The minimum VMA related to the
nominal aggregate size are shown in Table 6403/12.
Table 6403/12: Minimum VMA Specified for AC Mixes
Nominal maximum Minimum VMA (%)

aggregate size (mm) VIM = 4.0 % VIM = 5.0%
37.5 11.0 12.0
25 12.0 13.0
19 13.0 14.0
12.5 14.0 15.0
9.5 15.0 16.0
While the VMA is crucial to the correct volumetric design of HMA it is important to be aware of the
possible limitations in rigidly specifying values and also of the difficulties in accurately measuring VMA.
The variation in bitumen content with change in maximum aggregate size should actually be related to
the surface area of all of the aggregate particles in an HMA. However, in most cases, it will not be
possible to determine absolute values for surface area and will rely on determinations of VMA.
The measurement of VMA is subject to large variability with typical standard deviations of 1.3 per cent.
This is a large value in comparison to the incremental steps given in the normal specifications shown
in Table 6403/12. Furthermore, two particle size distributions having different maximum sized
aggregate but different aggregate types may have similar surface areas and hence require the same
minimum VMA.
Hence, the bitumen film thickness (i.e. the nominal thickness of non-absorbed bitumen coating the
aggregate particles) shall be calculated, as shown in Appendix C of the Pavement Design Manual,
Volume 1 Flexible Pavements 2013, and used to assist in the design process. If the bitumen film
thickness is less than 8 microns the determination of VMA shall be reviewed by the Engineer.
Evidence from field compaction trials, including the volumetric properties of cores cut from the trials,
shall be used to confirm that the mix is sufficiently workable and that specified properties are obtained.
The AC mix design using the Marshall method is based on three categories of design traffic:
 < 5 million esa;

 > 5 million esa; and
 Severe sites. These are sites where heavy traffic is slow moving, accelerating or braking and
include steep gradients, climbing lanes and junctions. (For guidance, a steep gradient is
defined as greater than 7 per cent but anywhere where heavy trucks are reduced to speeds of
less than 15 km/hour are severe sites).
The effect of VMA and of errors in the selection of the level of compaction that should be used is
discussed further in Appendices C, D and E of the Pavement Design Manual, Volume 1 Flexible
Pavements 2013.
(ii) Mix design for traffic < 5 million ESA.

In principle any AC wearing course or binder course gradings can be used as a running surface for
traffic loading up to 5 million ESA. The larger stone mixes have to be placed in thicker layers and the
surface finish of such mixes will have a coarser texture. All mixes shall be designed to the Asphalt
Institute (MS-2, 1994) Marshall criteria for wearing courses shown in Table 6403/13.
Table 6403/13: AC Wearing |Course Specifications for up to 5 million esa
No. of blows of
Category and design Min. VIM at optimum
Marshall Flow VFB
traffic Stability bitumen content
compaction (mm) (%)
(million ESA) (N) (%)
hammer
Heavy (1 - 5) 75 8000 2 - 3.5 65 - 75 4
Medium (0.4 – 1) 50 5300 2 - 4.0 65 - 78 4
Light (< 0.4) 35 3300 2 - 4.5 70 - 80 4
(iii) Mix design for traffic greater than 5 million ESA

Aggregate sources which are known to produce very stable mixes shall be used; and where
applicable, care must be taken to classify correctly lengths of road as ‘severe sites’ (See sub-clause
6403(b)(v) and to design a suitable mix for these locations).

The Marshall requirements for mixes designed for this category of design traffic are summarised in
Table 6403/14.
Table 6403/14: AC wearing course specification for more than 5 million esa
No. of blows of
Category and Min. VIM at optimum
Marshall Flow VFB
design traffic Stability bitumen content
compaction (mm) (%)
(million ESA) (N) (%)
hammer
Very heavy (> 5) 75 9000 2 - 3.5 65 - 73 5
(iv) Other considerations for design of continuously graded mixes

When a given aggregate blend is compacted in the Marshall test, VMA decreases as the bitumen
content is increased until a minimum value of VMA is obtained. Thereafter, more bitumen causes an
increase in VMA, indicating that the aggregate structure is becoming overfilled with bitumen, and will
result in the mix being susceptible to plastic deformation. It is important therefore, that the design
bitumen content is slightly less than that which gives the minimum VMA at the selected compaction
level.
(v) Mix design for severe sites

Without sufficient knowledge of the degree of secondary compaction that will occur on severe sites
any selection of a level of Marshall compaction becomes arbitrary. In comparison, compaction to
refusal provides a ‘reference density’ because the aggregate structure cannot be compacted any
further. Particle size distributions can, therefore, be selected to give VMA that will accommodate
sufficient bitumen to ensure good workability during construction and retain a minimum of 3 per cent
VIM at refusal density. However, it is important that a compromise is reached between high VMA to
accommodate enough bitumen to make the mix workable and sufficient fines to provide a strong mix.
It is also important that the coarse aggregate is strong enough to withstand vibratory compaction
without significant breakdown of the particles.
Dense wearing course mixes with low VMA will not be suitable for this type of surfacing because the
design bitumen content will be too low for the mix to be workable.
Suitable particle size distributions to begin the design process are given in Tables 6403/4 and 6403/6
which allow maximum particle size up to 37.5mm. A Marshall design should be carried out on the
selected mix but with no aggregate larger than 25mm. The Marshall design shall meet the
requirements for stability and flow given in Table 6403/14 for very heavy traffic.
If the Marshall requirements are satisfied then coarse aggregate between 25mm and 37.5mm, or
25mm and 28mm, depending upon the particle size distribution selected, may be included in the final
mix if desired. This will provide a better balance between maximum particle size and the thickness of
the layer to be constructed. The additional coarse aggregate should be from the same source as the
aggregate used in the Marshall design.
The particle size distribution given in Table 6403/4 allows up to 10 per cent of aggregate particles
between 25mm and 37.5mm. However, restricting this to a maximum of 5 per cent may also result in
less of a problem with segregation, which can be evaluated during pre-construction compaction trials.
A binder course aggregate grading having a maximum particle size of 28mm and complying with Table
6403/6 will often be a good compromise.
It is recommended that HMA designed to refusal density is laid to a compacted thickness of 2.5 to 4
times the maximum aggregate particle size to obtain satisfactory workability. The layer thickness can,
therefore, range from 70mm to more than 100mm for particle size distributions complying with Tables
6403/4 and 6403/6.
Compaction to refusal could be achieved in the laboratory by applying several hundred blows of the
Marshall hammer to each face of the test briquettes but this is not practical. The preferred method is to
use an electric vibrating hammer which is more representative of field compaction, and is a much
quicker operation. The test method is based on the Percentage Refusal Density (PRD) test
(Appendix E of the Pavement Design Manual, Volume 1 Flexible Pavements).
The test moulds for this method are large enough to allow the design of mixes containing aggregate
particles larger than 25mm. The apparatus is easily transportable and can be used to compact hot mix
samples anywhere on site provided a suitable power source is available.
The design bitumen content is determined by compacting samples to refusal using the method
described in Appendix E of the Pavement Design Manual, Volume 1 Flexible Pavements. The
thickness of the compacted samples shall be approximately the same as the compacted layer to be
laid on the road. Samples shall be made at the bitumen content which gives 6 per cent VIM in the
Marshall test and at decreasing increments of 0.5 per cent until the bitumen content which gives the 3
per cent VIM at refusal density can be identified.
The mix shall be workable at the design bitumen content. If necessary, the particle size distribution
must be adjusted until VMA is high enough to accommodate sufficient bitumen. A minimum calculated
bitumen film thickness (see Appendix C of the Pavement Design Manual, Volume 1 Flexible
Pavements). of 7 to 8 microns is a good indicator of a workable mix. However, the overriding
requirement is that at refusal density the VIM is 3 per cent. Pre-construction compaction trials are
essential to the selection of the final mix.
(vi) Grade of bitumen

50/70 penetration grade bitumen shall generally be used for HMA. For severe sites, the additional mix
stiffness that should result from using 35/50 penetration grade bitumen or a modified binder may be
justified with an appropriate increase in mixing temperature.
(vii) Mix design for Dense Bitumen Macadams

DBMs are essentially continuously graded HMAs and their design is similar to that of the continuously
graded HMAs described in sub-clause 6403(b)(i).
The Marshall mix design requirements are shown in Table 6403/15
Table 6403/15: Marshall criteria for Dense Bitumen Macadams
Design traffic (106 esa) Severe

< 1.5 1.5 - 10 >10
sites
Flow (mm) 2-4 2-4 2-4 2-4
Minimum stability 3.5 6.0 7.0 9.0
Compaction level (number
250 275 To refusal To refusal
of blows)
(viii) Mix design for Gap-graded mixes

The design method is described in the Sabita Interim Guidelines for the design of HMA in Southern
Africa.
(ix) Mix design for open graded mixes

Their design is described in the Sabita Manual 17 The design and use of porous asphalt mixes.
(c) Mix Design Specifications for Recycled Asphalt

The fundamental requirements for mix design of recycled asphalt are the same as for a mix containing
entirely fresh material described in sub-clause 6403(e). Problems that arise when Recycled Asphalt

Pavement (RAP) is incorporated into an HMA are mainly associated with the quality and
characteristics of this material. Guidance on the use of RAP is given in Appendix G of the Pavement
Design Manual, Volume 1 Flexible Pavements.
For recycled asphalt the nominal mix ratios of recovered asphalt, new aggregate, new bituminous
binders, and active mineral filler to be used for tender purposes, shall be as specified in the Particular
Specifications
(i) Asphaltic materials for hot plant mix recycling - recovered asphaltic mixes
The Engineer will test the existing asphaltic materials in any part of the project and determine its
suitability for recycling before removal. He may instruct the Contractor to drill additional cores at
specified points. Recovered asphalt intended for recycling shall be stored/stockpiled separately from
other asphalt, and the Engineer may also direct different types of recovered asphalt to be
stored/stockpiled separately.
The recovered asphalt shall be free from any underlying base material and other foreign matter.
Asphalt milled out of an existing pavement shall have a maximum size of 37.5 mm, unless otherwise
Asphalt not milled out shall be broken down in any approved manner so that it can be properly
remixed in a plant to the satisfaction of the Engineer. Mixes of recycled asphalt containing fragments
of recovered asphalt exceeding 37.5 mm in size, shall be rejected by the Engineer.
Payment for recovered asphalt will distinguish between milled out and non-milled out material.
Samples shall be taken from the recovered asphalt intended for hot recycled mixes in the stockpile
and shall be tested for grading and quality of the aggregate, binder content, and properties of the
binder.
(ii) Bituminous binders

The provisions of sub-clause 6402(b) shall apply.
The grade of new binder used in the recycled asphalt mix shall be such that the mix of new and
residual binder will comply with the requirements of the Particular Specifications.
Recycling agents such as blended oils and other additives may not be used without prior approval by
the Engineer.
(iii) New Aggregate

New aggregate required for use in recycled asphalt mixtures shall comply with the requirements of
sub-clause 6402(c).
(iv) Combined Aggregate

The aggregate mix obtained from new aggregate and the aggregate in the recovered asphalt,
including any mineral filler, an approved quantity of which may be added in accordance with sub-
clause 6403(a)(viii), shall comply with the requirements specified in the Particular Specifications for the
relevant recycled asphalt layer.
(v) Storing material for recycling

The provisions of Clause 5306 shall apply to the storing of recovered asphalt.

In addition the following requirements shall apply:
 Stockpiles of milled or crushed asphalt shall be shaped and formed in a manner that will
prevent segregation as far as possible. The stockpiling of the recovered asphalt shall be done
in a manner that will prevent consolidation as far as possible; and adequate covers shall be
provided to prevent the ingress of water and contamination by dust.
 The recovered asphalt that is placed in the stockpile(s) shall be tested, carefully controlled and
recorded with regard to origin and material properties to ensure a consistent recycled end
product.
 The preparation of stockpile sites and the stockpiling of recovered asphalt for recycling will not
be paid for directly but full compensation therefore shall be included in the rates for the
recycled asphalt.
(vi) Hot in-situ surface recycling

Hot in-situ surface recycling shall comply with the requirements in the Particular Specifications with
regard to new binder, recycling additives, new asphaltic mixes, new aggregate or combinations of
these materials.
(vii) Mixing plant.

Before work is commenced, the Contractor shall submit full details of his mixing equipment to the
Engineer for his approval.
In addition to the requirements set out in sub-clause 6405(b), the mixing equipment shall be specially
adapted for recycling in accordance with the manufacturer’s recommendations. The recovered asphalt
portion of the mix shall not be exposed directly to the heating source.
(d) Fibres
The use of fibres in asphalt mixes shall be subject to the provisions of the Particular Specifications.
(e) Asphalt reinforcing

Asphalt reinforcing shall be of the type specified in the Particular Specifications and shall be obtained
from an approved manufacturer.
Where the use of reinforcing for asphalt has been specified, at least 3 months before the material is to
be used the Contractor shall submit to the Engineer for approval samples of the type intended for use,
together with complete specifications of the material and the manufacturer's instructions for use.
Where the material does not carry the verification mark of an approved authority, the Engineer may
instruct the Contractor to have the material tested by an approved laboratory and to submit the results.
6404 Production of a Job (or Working) Mix

The mix proportions of bituminous binder, aggregates and fillers which are given in sub-clause
6403(a), are nominal proportions and shall only be used for tendering purposes. The application rates
and mix proportions actually used shall be determined to suit the materials used and conditions
prevailing during construction and any approved variation on a nominal mix in the bitumen content or
active filler content shall be the subject of an adjustment in payment for binder or active filler variations
as described in Clause 6416.
Before production or delivery of the asphalt the Contractor shall submit samples of the materials
proposed for use in the mix, together with the proposed mix design as determined by an approved
laboratory, to the Engineer in accordance with Table 10104/1, to enable the Engineer to test the
materials and confirm the use of the proposed mix provided the Engineer is satisfied that it meets the

specified requirements. The Engineer may change aggregate blends in order to allow the selection of
any combined aggregate grading for the proposed mix with the minimum bitumen content as specified
in the nominal mix proportions (by mass) of the various asphalt mixes as set out in the relevant Table
of sub-clause 6403(a).
As soon as the materials become available the Contractor shall produce a job mix in the plant in
accordance with the design mix. The job mix shall be tested by the Contractor for compliance with the
design requirements. Samples of the job mix and the test results shall be submitted to the Engineer for
approval and authorisation of the use of the job mix formula (or proportions) for use in the trial section.
Final approval of the job or working mix will be subject to the approval of the trial section. The
composition of the approved mix shall be maintained within the tolerances given in sub-clause
6414(c).
(a) General
All plant and equipment shall be so designed and operated as to produce a mixture complying with the
requirements of this specification. The plant and equipment used shall be of adequate rated capacity;
in good working order; and subject to the approval of the Engineer. The use of obsolete or worn-out
plant or equipment shall not be permitted on the Works.
Prior to the start of the work the Contractor shall supply the Engineer with copies of the manufacturer's
handbooks and copies of check lists prepared in terms of ISO 9002 (where applicable) pertaining to
the mixing, remixing and paving plant and equipment, containing details of the correct settings and
adjustments of the plant and equipment.
Any alteration which has been effected to any construction plant or equipment, and which does not
comply with the specifications of the manufacturer, shall be brought to the notice of the Engineer.
(b) Mixing plant
(i) Conventional binders

Asphalt shall be mixed by means of an approved type mixer of proven suitability for producing a
mixture complying with all the requirements of the specifications.
The mixing plant may be either automatically or manually controlled but in the latter case, two control
operators shall be provided.
The heating system of the tanks storing the binder shall be so designed that the binder will not be
degraded during heating. A circulating system for the binder shall be provided which shall be of
adequate size to ensure the proper and continuous circulation between storage tanks and mixer
during the entire operating period.
Binder storage tanks shall be fitted with thermometers designed to provide a continuous record of the
temperature of the binder in the tank. Copies of these records shall be supplied to the Engineer on a
daily basis.
Satisfactory means shall be provided to obtain the proper amount of binder in the mix within the
tolerances specified, either by weighing or volumetric measurements. Suitable means shall be
provided for maintaining the specified temperatures of the binder in the pipelines, weigh buckets,
spray bars and other containers or flow lines.
In the case of a drum type mixer, the system shall control the cold feeding of each aggregate fraction
and of the filler by mass, by means of a load cell or another device regulating the feed automatically,
and by immediately correcting any variation in mass which results from moisture or from any other

cause. The cold feed shall be regulated automatically in regard to the binder feed so as to maintain the
required mix proportion.
Suitable dust collecting equipment shall be fitted to prevent pollution of the atmosphere in accordance
with the provisions of Ethiopian Environmental Protection Authority (EEPA) Regulations.
The fuel chosen and control of the burner shall be such as to ensure the complete combustion of the
fuel in order to prevent pollution of the atmosphere and the aggregate.
(ii) Non-homogeneous modified binders (bitumen-rubber)

In the event of on-site blending adequate and suitable heating tanks and acceptable blending
equipment shall be provided in addition to the mixing plant for conventional binder.
(iii) Homogeneous modified binder

In addition to the mixing plant requirements for conventional binder, refer to the requirements of the
(iv) Recycled material

Before work is commenced, the Contractor shall submit full details of his mixing equipment to the
Engineer for his approval.
In addition to the requirements set out in sub-clause 6405(b)(i), the mixing equipment shall be
specially adapted for recycling in accordance with the manufacturer’s recommendations. The
recovered asphalt portion of the mix shall not be exposed directly to the heating source.
(c) Spreading equipment
(i) Paver
The mixture shall be laid by an approved type of self-propelled mechanical spreader and finisher
capable of laying the mixture to the required widths, thicknesses, profile, camber or cross-fall, without
causing segregation, dragging or other surface defects.
All pavers shall be fitted with automatic electronic screed controls to maintain the required levels,
cambers and cross-falls.
Where levelling beams on multiple skids or sliding beams are used they shall be at least 12.0 m long,
or as specified by the Engineer.
(ii) Chip spreader

Wherever feasible, a machine straddling the full paved width shall be used for spreading the pre-
coated chippings. Such a mechanical spreader must be self-propelled and be able to follow
immediately behind the paver.
When pre-coated chippings are spread by hand special care shall be taken to prevent bunching of the
chippings.
(d) Rollers
(i) General requirements

Compaction shall be done by means of approved steel-tyred flat rollers, vibratory rollers or pneumatic-
tyred rollers. The frequency as well as the amplitude of vibratory rollers shall be adjustable. Vibratory
rollers shall be used only where there is no danger of damage being done to the asphalt, structures of
bridge decks, or other layers. The Particular Specifications shall indicate whether vibratory compaction
equipment may be used on bridge decks and outline the constraining parameters. The rollers shall be
self-propelled and in good working condition, free from back lash; faulty steering mechanism; and
worn parts Rollers shall be equipped with adjustable scrapers to keep the drums clean and with
efficient means of keeping the wheels wet to prevent mixes from sticking to the rollers.

No leakages of any nature may occur in the rollers.
The mass and/or tyre pressures shall be such as to ensure proper compaction to comply with the
specifications of surface finish and density.
(ii) Non-homogeneous modified binder asphalt

For continuously graded asphalt the use of an approved pneumatic-tyred roller shall be assessed in a
trial section. The Contractor shall take adequate precautions to eliminate pick-up.
For open-graded asphaltic mixes and/or stone-mastic asphaltic mixes, only approved static steel-tyred
flat rollers having a total mass of 7 to 10 tons shall be used.
(iii) Homogeneous modified binder asphalt

The general requirements shall apply. However, for open graded asphalt and/or stone-mastic asphalt
the requirements as specified for non-homogeneous modified binder asphalt shall equally apply.
(e) Binder distributors

Where bituminous binders are to be sprayed onto areas before the asphalt is placed, the binder
distributors shall comply with sub-clause 6304(b).
(f) Trucks for transporting asphaltic mixes

The asphaltic mixes shall be transported from the mixing plant to the spreader in trucks having cargo
trays with beds and sides, which are clean and smooth, without gaps, holes or openings. The bed and
sides shall be treated to prevent adhesion of the mixture to the truck bodies. A thin film of soapy water
or vegetable oil may be used to prevent adhesion but petroleum products shall not be used for this
purpose.
All trucks used for transporting hot asphalt shall be equipped with waterproof canvas covers, insulated
metal sheets or other suitable approved covers to minimise temperature loss from the asphaltic mix.
Such covers shall be securely fixed over the hot asphaltic mix from the time of loading at the mixing
plant until immediately prior to the discharge of the asphaltic mix into the paver.
(g) Mass-measuring device for asphalt mixes

Where payment per tonne is specified, the Contractor shall keep available at the mixing plant or on the
site a suitable gauged mass-measuring device for measuring the asphalt mixes. The device shall be
provided with a printer for printing the type of mix, the mass, the time and the date. The printed data
shall be submitted to the Engineer.
6406 General Limitations and Requirements and the Storage of Mixed Material
(a) Weather conditions

Asphaltic mixes may be mixed and placed only under favourable weather conditions, and shall not be
mixed or placed when rain is imminent or during misty or wet conditions.
The following wind and temperature conditions are deemed to be suitable for asphaltic paving work:
 While the air temperature is rising, ambient air temperature not less than 6ºC and a wind
velocity of less than 25 km/h
 While the air temperature is rising, ambient air temperature not less than 10ºC and a wind
velocity of less than 55 km/h, or for compacted thicknesses of less than 30 mm, with a wind
velocity of less than 25 km/h.
 With falling air temperatures, work must stop when the temperature reaches 6ºC regardless of
the wind velocity and may not be restarted before the temperature is definitely rising.

(b) Moisture
The mixing and placing of asphaltic mixes will not be allowed if:
 The moisture content of the aggregate affects the uniformity of temperature;

 Free water is present on the working surface;
 In the opinion of the Engineer, the moisture content of the underlying layer is too high; or the
moisture content of the upper 50 mm of the road base exceeds 50% of the optimum moisture
content as determined by the Engineer
No overlay shall be placed immediately after a rainy spell on an existing partly cracked and/or highly
permeable surfacing resulting in the trapping of moisture in the pavement structure. In such events, a
minimum delay of 24 hours or such extended period as ordered by the Engineer shall apply.
(c) Surface requirements
(i) Correction of base layer (and sub-base in the case of asphaltic basecourse)
The base (after the prime coat has been applied) or the sub-base, as the case may be, shall be
checked for smoothness and accuracy of grade, elevation and cross section. Any portion of the base
or sub-base which does not comply with the specified requirements shall be corrected with asphaltic
material, at the Contractor's own expense, until the specified requirements are met. However, the
Engineer may, at his sole discretion, allow minor surface irregularities to remain, provided they can be
taken up in the following asphaltic layer without adversely affecting that layer.
The asphalt used for the correction of the base or sub-base shall be the same mixture as specified for
the surfacing or as directed by the Engineer, and the maximum size of aggregate used shall be
dictated by the required thickness of the correction in each case.
Notwithstanding these provisions for the correction of the base or sub-base, the Engineer may order
the removal and reconstruction of the layer or of portions of the base and sub-base layers not
complying with the specified requirements, instead of allowing the correction of substandard work with
asphaltic material.
Where a prime coat is applied it shall be dry before further coats or layers are applied. The Contractor
shall not commence with the application of the tack coat and/or the paving without the written approval
of the Engineer.
The Contractor's Programme shall allow for delays that are a function of the type of prime; rate of
application; base porosity and moisture content; and climatic conditions.
(ii) Cleaning of surface

Immediately before applying the tack coat, or where there is no tack coat, before the application of the
asphaltic layer, the surface shall be broomed and cleaned of all loose or deleterious material.
Where the prime coat (if any) has been damaged, it shall be repaired by hand-brushing or spraying
priming material over the damaged portions.
Where the surfacing is to be constructed on bridge decks, the concrete deck shall be thoroughly
cleaned by washing and brushing to remove all loose material and allowed to dry.
(iii) Tack coat

A tack coat shall be applied to the surface to be paved to the requirements of Division 6200.

(iv) Preparation for placing the overlays

The provisions of Division 6600 shall apply to any surface to be covered with overlays. The type of
treatment to be applied, if any, will be specified in the Particular Specifications or instructed in writing
by the Engineer.
(v) Preparation where asphalt layers are to be widened or where surfacing over a section of the
road width requires replacement
The existing asphalt shall be removed as described in section 5300, where applicable, or as instructed
by the Engineer.
Where a road has to be widened, the overlay shall be cut back not less than 100 mm from the existing
edge. Unless otherwise indicated on the Drawings or instructed by the Engineer, asphalt joints may
not fall within a wheel track.
(d) Storage
Mixing shall not be allowed to take place more than four (4) hours before paving begins unless
provision has been made for storage. Storage of mixed material will only be permitted in approved
hoppers, which are capable of maintaining the temperature of the mix uniformly throughout In any
case, storage will not be permitted for a period longer than eight (8) hours after mixing, unless
otherwise approved by the Engineer. Open-graded mixes and stone-mastic asphalt shall not be stored
or mixed ahead of paving operations but shall be laid directly after mixing.
6407: Producing and Transporting the Mixture
(a) Mixing and storage temperatures of binder and asphaltic mixes

Bituminous binders shall be stored at temperatures not exceeding those given in Table 6407/1, Table
6407/2 or as specified in the Particular Specifications. The temperature ranges for the asphalt mixes at
the mixing plant are also given in the respective Tables.
Table 6407/1 Temperature requirements for asphaltic mixes with conventional binders
Maximum storage temperature

Temperature range of asphaltic mixes (°C)
of binder (°C)
Binder type Continuously,
More than Less than
Semi-gap graded, Open graded mixes
24 hours 24 hours
Gap-graded mixes
35/50 penetration
145 175 140 - 165 110 - 140
grade bitumen
50/70 penetration
135 175 135 – 160 105 – 135
grade bitumen
Table 6407/2: Temperature requirements for asphaltic mixes with modified binders
Short-term Handling Storage Mixing

Max Max Max Max Max Min Max
Binder Class
Temp Holding Temp Holding Temp Temp Holding
(ºC) Time (hrs) (ºC) Time (hrs) (ºC) (ºC) Time (hrs)
A-E1 (SBR) 180 24 150 240 190 175 8
A-E1 (SBS) 180 24 150 240 180 170 12
A-E2 180 24 150 240 180 170 12
A-P1 180 24 150 240 170 150 24
A-R1 165 24 150 240 210 190 4

(b) Production of the mixture
(i) Using batch plants

 Heating the aggregate
The aggregate shall be dried and heated so that when delivered to the mixer the temperature shall be
between 0°C and 20°C lower than the maximum temperature indicated in Tables 6407/1 and 6407/2
for the mixture.
The moisture content of the mix shall not exceed 0.5%.
 Batching
Each fraction of the aggregate and binder shall be measured separately and accurately in the
proportions by mass in which they are to be mixed. If filler is used it shall be measured separately on a
scale of suitable capacity and sensitivity. The error in the weighing apparatus used shall not exceed
2% for each batch.
 Mixing
The aggregate filler and binder shall be mixed until a homogeneous mixture is obtained in which all
particles are uniformly coated. Care shall be taken to avoid excessively long mixing times which can
cause hardening of the binder.
(ii) Using drum-type mixer plants

The aggregate and filler shall be accurately proportioned and conveyed into the drum-mixing unit. The
calibrated amount of binder shall be sprayed onto the aggregates at the correct position so that no
hardening of the binder shall take place. A homogeneous mixture and uniform coating of binder must
be achieved and the moisture content of the asphalt mixture shall not exceed 0.5%. Once the final mix
temperature has been agreed upon it may not be altered without the prior consent of the Engineer.
The moisture content of the asphalt mixture shall be tested according to method BS EN 12697-14.
(c) Transporting the mixture

The mixture shall be transported from the mixing plant to the works in trucks complying with the
requirements of sub-clause 6405(f). Loads shall be covered by waterproof canvas or insulated metal
sheets when the haul exceeds 10 km or during cold, windy or rainy weather. Deliveries shall be made
so that spreading and rolling of all the mixtures prepared for a day's run, can be completed during
daylight, unless artificial lighting, as approved by the Engineer is provided. Any asphalt which has
become wet due to rain or any other cause shall be rejected.
Hauling over freshly laid material is not permitted.
(d) Small quantities of asphalt

Extra payment will be made for the special production of a quantity of asphaltic mix of less than
10 tonnes, if such special production has been deemed by the Engineer to be necessary in
accordance with the approved working programme of the Contractor; and/or for the safety of the work
or the travelling public on account of weather conditions or abnormal traffic conditions.
No extra payment will be made where small quantities of asphaltic mixes are required in consequence
of the negligence of the Contractor; or of poor work or bad planning by the Contractor; or because the
Contractor did not execute the works in accordance with his approved programme.
(e) Recycled asphalt

The provisions of sub-clauses 6407(a) to 6407(d) shall apply.

At least 4 weeks before paving with recycled material will commence, the Contractor shall submit to
the Engineer full particulars regarding the recycling methods the Contractor intends to use.
Where recovered asphalt material is taken from a stockpile, it shall be done by excavating from the
pile over its full depth and the feeding rate and proportioning at the mixing plant shall be accurately
controlled.
Segregated material shall not be fed into the mixing plant. The Engineer may order the Contractor to
remix segregated stockpiles, retest the mixed material and redesign the asphaltic mixture all at the
cost of the Contractor.
6408 Spreading the Mixture
(a) General
The mixture shall be delivered to the paver in such a manner that the paver will never be forced to
stop due to lack of asphalt. The temperature of the mixture shall be controlled by measuring in a
random pattern in the truck immediately before emptying and shall not be more than 10°C below the
minimum temperature specified for mixing specified in sub-clause 6407(a). The adjustment of the
screed, tamping bars, feed screws, hopper feed, etc, shall be checked frequently to ensure uniform
spreading of the mix. If segregation or tearing occurs the spreading operations shall immediately be
suspended until the cause is determined and corrected.
The addition and removal of material behind the paver shall normally not be allowed and the paver
shall be capable of spreading the mixture to the correct amounts that will provide the required
compacted thickness without resorting to spotting, picking-up or otherwise shifting or disturbing the
mixture.
Only minimal hand-working of the open graded asphalt shall be permitted after discharge from the
paver and before rolling and shall only be carried out with wooden spreaders. Operatives shall not be
permitted to walk on uncompacted open graded asphalt.
Paving shall, if possible, commence at the bottom of the grades and the lower edges of superelevated
curves. Paving shall be carried out up the grade on grades steeper than 5%.
Spreading shall be so arranged that longitudinal joints do not coincide with joints in lower layers of the
asphalt base, paver laid crushed stone bases or existing surfacing.
Continuity of placing is especially important for open-graded asphalt. Cutting of longitudinal joints shall
be avoided when paving open-graded asphalt, but where cutting is essential, only sawing shall be
permitted. The existing layer shall be heated to assure adequate longitudinal bonding of the asphalt in
the two lanes.
Unless otherwise specified in the Particular Specifications the paver shall be equipped to provide
automatic control of levels and cross section. In the case of asphaltic road base construction,
automatic control shall be run off guide wires and in the case of surfacing and overlays skids or guide
wires shall be used.
On restricted areas, inaccessible to the paving equipment used, the mixture may be placed by hand or
other means to obtain the specified results. Paving shall be carried out in a manner which will avoid
segregation and which will allow control of levels.
The mixer capacity and the operating speed of the paver are to be so co-ordinated as to ensure
continuous laying and to avoid intermittent stopping of the paver.
Paving shall cease when rain starts falling or when, in the opinion of the Engineer, the surfaces to be
paved are visibly wet.

(b) Overlays
In the case of overlays, guide wires will normally not be required during the placing of the mix unless
specified in the Particular Specifications. In all cases, including levelling courses, the paver shall be
provided with approved skid beams with electronically controlled equipment, which can ensure a
constant crossfall and can even out local irregularities.
(c) Restricted areas

Asphaltic mixes shall be placed in restricted areas with the aid of smaller specially equipped pavers,
hand tools or other approved equipment. The space concerned shall be properly filled with asphalt,
without leaving any gaps between the fresh asphalt and the existing pavement layers.
All the provisions in regard to temperature, mix composition, uniformity, etc. shall remain applicable
but layer thickness and control shall be such that the requirements for compaction and surface
tolerances can still be attained.
(d) Recycled asphaltic mixes

The provisions of sub-clauses 6408(a) to 6408(c) shall also apply to recycled asphalt.
Where the average thickness of a completed asphaltic layer exceeds the specified thickness, and/or
recovered asphalt has been wasted indiscriminately; and if, in the opinion of the Engineer, it has
resulted in a deficiency of recovered material, the Contractor shall supplement such deficiency at his
own cost with a quantity of similar or better material equal to the quantity wasted, as determined by the
Engineer.
6409 Joints
All joints between adjacent sections of the work shall be made by cutting back the layer against which
the material is to be placed except for open-graded asphalt where the requirements of sub-clause
6408(a) shall apply. All loose and incompletely compacted material shall be removed. A cutting wheel
shall be used for cutting longitudinal joints.
The joints of adjacent sections shall normally not be cut in the case of open-graded surfacing, but shall
be formed by placing hot asphalt in the adjacent lanes.
Joints shall be either at right angles or parallel to the centreline, and unless otherwise approved joints
in the final layer of the surfacing shall correspond with the lane markings. Joints in lower layers shall
be offset not less than 150 mm on either side of the edges of the traffic lanes.
Before a new layer is placed next to an existing layer, except in the case of open-graded mixes, if so
directed by the Engineer, the cut edge of the existing layer shall be painted with a thin coat of
bituminous emulsion of the same type used for the tack coat.
Joints shall be neat and shall have the same texture and density as the asphalt course. All joints shall
be marked out with chalk lines prior to cutting.
The outside edges of the completed asphalt layer shall be trimmed along the shoulder and parallel to
the centreline to give the finished width shown on the Drawings, within the tolerances specified.
Any fresh mixture spread accidentally onto existing work at a joint shall be carefully removed by
brooming it back with stiff brooms onto the uncompacted work so as to avoid the formation of
irregularities at the joint. Whenever the paving operation is stopped due to lack of mixture, the
Contractor shall form a proper joint as specified above, if so directed by the Engineer.
The requirements of this Clause 6409 shall also apply to joints in recycled asphalt layers.

6410 Pre-Coated Chippings for Asphalt Surfacing

Aggregate for pre-coated chippings shall be coated using 1.7% ± 0.3% by mass of the same bitumen
used in the asphaltic surfacing, provided that the bitumen shall not be softer than 60/70 penetration-
grade. One per cent by mass of active filler shall be added to the mixture.
The active filler shall be hydrated lime, and shall comply with the requirements of sub-clause
6403(a)(viii).
The aggregate shall be dried and fed into the mixer at a temperature of between 130°C and 185°C
followed by the bitumen (at a temperature not exceeding 175°C) and filler. Immediately after the
aggregate has been coated and discharged from the mixer it shall be rapidly cooled to ambient air
temperature by hosing down with water.
Coated chippings shall be stockpiled in heaps not exceeding 1.0 metre in height and, if necessary,
protected to prevent its temperature from exceeding 60°C during storage.
The pre-coated chippings shall be spread on the asphaltic surfacing at the rate of 6 to 8 kg/m² when
using 13.2 mm nominal size chippings, 7 to 9 kg/m² when using 19.0mm nominal size chippings,
depending on the relative density of the aggregate. The chippings shall be laid by a mechanical
spreader, which straddles the paved width and follows immediately behind the paver. The chippings
shall be spread to give a uniform texture free from clusters and open patches and rolled in as
described in Clause 6411. The desired surface texture shall be demonstrated in the trial section as
described in Clause 6412, and it shall have a texture depth of between 0.6 and 1.0 mm when tested
according to method BS EN 13036-1. Thereafter the spread rate shall be determined by the Engineer.
In restricted areas the Contractor may use hand tools for spreading chippings or, if so instructed by the
Engineer, after compaction of the asphaltic surfacing, the Contractor shall place a bituminous seal as
specified in Clause 6308; or in the Particular Specifications. The rate of application and requirements
for evenness of the spread chippings shall remain applicable.
Where extra over payment is made for work in restricted areas, no distinction shall be made between
placing the conventional chippings and placing the bituminous seal as specified in Clause 6308 or in
the Particular Specifications.
The provisions of this clause shall apply to surfacings of recycled asphalt, but the rate of application of
the stone chippings will be determined by the Engineer after the grading of the recovered asphalt and
the mix ratios of the recycled mix have been determined.
6411 Compaction
(a) General
The following requirements shall apply to rolling and compacting generally:
 The material shall not be excessively displaced in a longitudinal or transverse direction

especially when changing gears, stopping or starting rollers.
 No cracks or hair cracks shall be formed and the bond with the underlying layer shall not be
broken.
 The density shall be uniform over the whole area of the layer and extend over the full depth of
the layer.
 Rollers shall not be left standing on the asphalt layer before it has been fully compacted and
before the layer surface temperature has dropped below 60ºC.
 In restricted areas where the specified rollers cannot be used, compaction shall be carried out
with hand-operated mechanical compaction equipment or approved smaller vibratory rollers.
The prescribed density requirements remain applicable throughout over the full layer thickness
irrespective of the method of compaction.
(Note: The provisions of Clause 6411 shall also apply to recycled asphalt.)
The mix shall be rolled as soon as possible after it has been laid by a combination of vibratory and
non-vibratory steel-tyred flat rollers and pneumatic-tyred rollers in a sequence predetermined and
approved during the laying of trial sections. Such rolling shall commence and be continued only for so
long as it is effective and does not have any detrimental effect.
Only non-vibratory steel-tyred flat rollers will be permitted for the compaction of open-graded mixtures
although rubber-tyred rollers shall be on standby if required. The use of pneumatic-tyred rollers for
continuously-graded asphalt with modified binders shall be assessed in the trial section.
As many rollers shall be used as is necessary to provide the specified pavement density and the
required surface texture. During rolling of asphalt surfacing, the roller wheels shall be kept moist with
only sufficient water to avoid picking up the material.
After longitudinal joints and edges have been compacted, rolling shall start longitudinally at the sides
and gradually progress towards the centre of the pavement, except on superelevated curves, or where
the area to be paved has a cross-fall, when rolling shall begin on the low side and progress to the
higher side, uniformly lapping each preceding track, covering the entire surface. During breakdown-
rolling the rollers shall move at a slow but uniform speed (not to exceed 5 km/h) with the drive roller
nearest the paver, unless otherwise specified on account of steep gradients.
No movement of the asphalt layer shall occur under steel-tyred rollers once the asphalt temperature
has dropped to below 100°C. Three-wheeled steel-tyred rollers, with large diameter rear wheels are
preferable to tandem rollers and may be used in conjunction with pneumatic tyred rollers, provided
pick-up of the asphalt on the wheels does not occur.
The Contractor shall take adequate precautions to eliminate pick-up.
The sequence of rollers used in compaction is at the discretion of the Contractor provided the
completed pavement shall have a density as measured on recovered core equal to or greater than 97
per cent, minus the percentage voids in the approved production mix, of the theoretical maximum
density, determined as described in BS EN 12697-5.
For thin layer asphalt (less than 25 mm) the compaction requirements shall be specified in the
For open graded asphalt the degree of compaction can be controlled indirectly by means of in-situ
permeability tests calibrated during the trial section and by visual evaluation of the aggregate to
prevent crushing.
The Contractor shall utilize a calibrated nuclear gauge for process control during compaction
operations if approved by the Engineer or included in Particular Specifications (See sub-clause
10107(f)). However, all acceptance control carried out for compaction by the Engineer shall still be
based on the density of cores taken from the compacted layer.
When constructing asphalt surfacing with rolled-in chippings the asphalt shall be paver-compacted and
thereafter pre-coated chippings shall be spread at the specified rate. When the asphalt has reached
the correct temperature the chippings shall be rolled in so that they are firmly bedded in the asphaltic
mix. Care shall be taken to avoid rolling the chippings flush with the surface of the asphaltic layer but
to leave them slightly proud. The procedure for compacting the asphaltic material and rolling in the
chippings to produce the desired surface texture and specified degree of compaction shall be
determined on a trial section as described in Clause 6412.
The portion of trial section having the desired surface texture shall be designated as a reference
section for the requirement of the permanent work.
6412 Laying Trial Sections

No experimentation by the Contractor regarding the equipment and processes that he proposes to use
for the construction of asphaltic layers shall be allowed on the permanent work, unless so approved by
the Engineer.
Before the Contractor commences with the construction of any asphalt base or surfacing layer, the
2
Contractor shall demonstrate by laying a trial section of at least 500m in area, or as specified
(depending on the required layer thickness), that the equipment and processes proposed for use will
enable the construction of the particular asphaltic course in accordance with the specified
requirements.
The Engineer may require that up to three (3) different binder contents be incorporated in one such
trial section to verify the laboratory design phase.
Amongst other test results the Contractor shall submit dynamic test results obtained from the testing of
cores extracted from the completed trial section in locations determined by stratified random sampling
methods, and/or, if specified, dynamic test results obtained from briquettes prepared from material
obtained by stratified random sampling methods at the manufacturing plant or behind the paver as
A maximum period of 10 days shall be allowed to verify dynamic creep test results unless otherwise
specified in the Particular Specifications.
Only when such a trial section has been satisfactorily laid and finished, and complies with the specified
requirements, will the Contractor be allowed to commence with construction of the permanent work.
If the Contractor should make any alterations in the methods, processes, equipment or materials used,
or if he is unable to comply consistently with the specifications, the Engineer may require that further
trial sections be laid at the Contractor's cost before allowing the Contractor to continue with the
permanent work.
The trial sections shall be laid where indicated by the Engineer. The Contractor shall prepare the
surface on which to lay the trial section and shall also, if required, remove the trial section after
completion and restore the surfaces on which it was constructed, all at the Contractor's cost.
Provision is made for payment of the first approved trial section of any particular mix type, but
subsequent trial sections with the same mix type shall be at the Contractor's own cost. Payment will
be made for the specified area of each approved first trial section for any particular mix type.
The construction equipment and techniques as well as the mix properties applicable to the approved
trial section shall not be changed without prior approval by the Engineer.

The Contractor shall protect asphalt base and surfacings from all damage until the work is finally
accepted by the Engineer; and shall maintain the surfacing work until the issue of the maintenance
certificate. With the exception of fair wear and tear on the surfacing, any damage occurring to the
completed base or surfacing during the Defects Liability Period; or any defects which may develop due
to faulty workmanship; shall be made good by the Contractor at his own expense and to the

(a) Construction tolerances

The completed sections of asphaltic base and surfacing shall comply with the requirements for grade,
width, thickness, cross section and smoothness as follows.
The construction tolerances for overlays are shown in sub-clause 6414(f)
(i) Level and grade

The level tolerances referred to in Clauses 10205 and 10305 shall be as follows:
 H90 ± 15 mm
 Hmax ± 20 mm
Deviation from the specified longitudinal grade due to deviations from the specified levels shall not
exceed the values given in Table 6414/1.
Table 6414/1: Deviation from Longitudinal Grade

Length of Variation Maximum Variation from
in Grade (m) Specified Grade (%)
2 0.354
5 0.224
10 0.158
20 0.112
30 0.091
(ii) Width
The average width of both asphalt base and surfacing shall be at least equal to that shown on the
Drawings; and nowhere shall the outer edge of the layer be inside the lines shown on the Drawings by
more than 15 mm for both asphalt base and surfacing.
(iii) Thickness
The thickness tolerances are shown in Table 6414/2.
Table 6414/2: Thickness Tolerances

Base (mm) Surfacing (mm)
D90 15 5
Dmax 20 8
Dave 5 2
Thickness shall be determined from carefully controlled levels taken before and after construction in
exactly the same position and/or from cores drilled from the completed layer.
(iv) Cross section

When tested with a 3m straightedge laid at right angles to the road centreline the surface shall not
deviate from the bottom of the straight-edge by more than 6mm for expressways and by more than
10mm for other roads.
difference in level computed from the cross section shown on the Drawings by more than 15mm for
freeways and 20mm for other roads.

(v) Surface irregularity

When tested with a rolling straight-edge as described in Clause 10111 the number of surface
irregularities shall not exceed those given in Table 6414/3 (applied to base and surfacing)
Table 6414/3: Surface Irregularity Limits
Average number of Number of

irregularities per 100 m irregularities equal
Maximum value
equal to or exceeding to or exceeding
Road Type Asphalt Type of any individual
the specified value the specified value
irregularity (mm)
when taken over 300 m when taken over
- 600 m lengths 100 m sections
Asphalt Mixes
with rolled-in 5 8 5
chips
Expressways
Stone mastic
(< 3mm irregularities) 4 6 6
Asphalt
Other asphalt
3 5 4
layers
Asphalt Mixes
with rolled-in 4 6
Other Roads
chips 8
(< 5mm irregularities)
Other asphalt
2 3
layers
(vi) Multiple-layer base

Where the base is constructed from more than one layer, the requirements specified shall apply to the
combined layers in respect of width and thickness. The requirements for cross-section, smoothness
and grade shall apply to the final layer only but the lower layers shall be constructed so as to ensure
that these requirements in the final layer can be met.
(b) Spread rate of rolled-in chippings

The tolerance in the spread rate of rolled-in chippings shall be ±10% of the specified spread rate.
(c) Gradings
The combined aggregate and filler grading shall not deviate from the approved target grading for the
working/job mix by more than that given in Table 6414/4. The mean grading of each lot of the working
mix (minimum of 6 tests per lot) shall be determined from samples obtained in a stratified random
sampling procedure.
Table 6414/4: Deviation from approved target grading

Material passing Permissible deviation from
sieve size (mm) approved target grading (%)
26.5 ± 5.0
19.0 ± 5.0
13.2 ± 5.0
9.5 ± 5.0
6.7 ± 5.0
4.75 ± 4.0
2.36 ± 4.0
1.18 ± 4.0
0.60 ± 4.0
0.30 ± 3.0
0.15 ± 2.0
0.075 ± 1.0 *
* When statistical methods are applied the permissible deviation for the 0.075 mm fraction is ± 2.0%.

(d) Binder content

The binder content shall be within the limits specified in the applicable statistical judgement scheme in
Clause 10206 or Clause 10305.
(e) Voids
The voids in the mix (VIM, VFB and VMA) shall be within the limits specified in the applicable
statistical judgement scheme in Clause 10206.
(f) Construction tolerances for overlays

When the overlay is constructed to specified levels on a layer that has also been constructed or milled
to specified levels by the Contractor, all the tolerance requirements of sub-clause 6414(a) shall be
applicable.
When the overlay is constructed to specified levels on an existing bituminous layer, or on a layer which
has been constructed or milled by the Contractor, but which has not been constructed or milled to
specified levels, all the tolerance requirements of sub-clause 6413(a) shall be applicable except those
of sub-clause 6414(a) which relate to thickness.
When the overlay is not constructed to specified levels and no guide wires are used, but an
electronically controlled paver and a skid beam, the following tolerances shall apply:
 The outer edges of the overlay shall nowhere be more than 15 mm inside or outside the lines
shown on the Drawings, and shall be parallel to the road centreline;
 The minimum thickness shall be the specified nominal thickness;
 The maximum thickness shall be the specified nominal thickness ± 10 mm;
 The surface regularity shall be measured with a 3.0 m straight-edge in accordance with sub-
clause 10111 (b), and no irregularity may exceed 6 mm.
6415 Quality of Materials and Workmanship
(a) Sampling
Sampling of asphalt mixes shall be carried out according to method BS 598, or as prescribed by the
Engineer.
Sampling for acceptance control for bitumen content and grading shall be carried out immediately
behind the paver or as otherwise prescribed by the Engineer.
Sampling of bitumen shall be carried out at the discharge point of the delivery vehicle or adjacent to
the discharge point into the mixer. Bitumen sampling shall comply with the relevant procedure as
described in ASTM D140.
(b) Coring of asphaltic layers

If required in the Particular Specifications, the Contractor shall provide suitable coring machines
capable of cutting 100 mm diameter cores from the completed asphaltic layers. The Contractor will be
paid in accordance with item 64.08 for cutting cores ordered by the Engineer.
The cost of extracting cores for process control shall be included in the Contractor's prices for the
construction of asphalt pavement layers and will not be paid for separately. The coring equipment, the
programme, and the procedures must be approved by the Engineer.

If the Contractor does not adhere to the approved programme, the Engineer may temporarily suspend
the paving operations.
All core holes shall be neatly repaired with asphalt and compacted to the specified density. Wherever
possible the cores shall be filled with the same mix as used for the layer tested.
(c) Routine inspection and tests

Routine inspection and tests will be carried out by the Engineer to determine the quality of the
materials and workmanship for compliance with the requirements of this section.
Tests results and measurements will be assessed in accordance with the provisions of Divisions
10200 or 10300; or as specified in the Particular Specifications.

Items 64.12, 64.13 and 64.15 are applicable solely to work that has to be executed in a restricted area
of which the width is less than 3m or the length is less than 150m.
Item 64.01 Bituminous road base

{State thickness, type of bitumen and maximum size of aggregate}
(a) Continuously graded ................................................................................. square metre (m²)
(b) Gap-graded............................................................................................... square metre (m²)
(c) Dense Bitumen Macadam ........................................................................ square metre (m²)
The unit of measurement shall be the square metre of asphaltic base constructed to the thickness
specified. No payment will be made for material wasted.
The tendered rates shall include full compensation for procuring, furnishing, transporting, heating,
mixing, placing and compaction of all materials as well as process control testing, protecting and
maintaining the work as specified.
Item 64.02 Asphaltic surfacing

{State thickness and type of bitumen}
(a) Continuously graded (state grade) ........................................................... square metre (m²)
(b) Gap-graded (state stone content) ............................................................ square metre (m²)
(c) Open-graded (state grade) ....................................................................... square metre (m²)
(d) Stone-mastic asphaltic (state maximum size of aggregate) ..................... square metre (m²)
(e) Dense Bitumen Macadam ........................................................................ square metre (m²)
The unit of measurement shall be the square metre of asphaltic surfacing constructed to the thickness
specified. No payment will be made for material wasted
The tendered rates shall include full compensation for procuring, furnishing, transporting, heating,
mixing, placing and compaction of all materials as specified as well as process control testing,
protecting and maintaining the work as specified.
Rolled-in chippings will be paid for separately under item 64.03.

Item 64.03 Rolled-in chippings in surfacing (State nominal size) ................ square metre (m²)
The unit of measurement shall be the tonne of rolled-in chippings applied at the specified rate,
measured loose in hauling vehicles.
The tendered rate shall include full compensation for the procuring, furnishing, pre-coating,
transporting, spreading and rolling-in of pre-coated chippings and for any additional costs resulting
from more difficult construction of the asphalt surfacing with rolled-in chippings
Item 64.04 Tack coat of 30% stable-grade bitumen emulsion ........................................ litre (ℓ)
The unit of measurement shall be the litre of 30% stable- grade emulsion applied as specified.
The tendered rate shall include for the procuring, furnishing, transporting and application of the
material as specified.
Item 64.05 Binder variations (state type) ..................................................................... tonne (t)

The unit of measurement in respect of increases or decreases in the bituminous binder from that
specified in the nominal mix (see Clause 6403) shall be the tonne.
Payment for variations shall be made as specified in sub-clause 0103(g).
Item 64.06 Variation in active filler content

(a) Cement ................................................................................................................... tonne (t)
(b) Lime ........................................................................................................................ tonne (t)
(c) Milled granulated blast-furnace slag ....................................................................... tonne (t)
(d) Fly-ash .................................................................................................................... tonne (t)
The unit of measurement in respect of increases or decreases in the active filler content for base and
surfacing mixtures from that specified in the nominal mix (see Clause 6403) shall be the tonne. No
payment shall be made for inert filler added by the Contractor.
Payment for variations shall he made as specified in sub-clause 0103(g).
Item 64.07 Trial sections (state nominal thickness) ........................................ square metre (m²)
The unit of measurement shall be the square metre of trial section using asphaltic mix constructed as
ordered.
The tendered rate shall include full compensation for the construction of the trial section of asphaltic
layer complete as specified, for the application of a prime coat and for the application of rolled-in pre-
coated chippings, if specified.
Item 64.08 100mm diameter cores in asphaltic layers ........................................ number (No)
The unit of measurement shall be the number of 100 mm diameter cores drilled and recovered as
instructed by the Engineer for his own testing. No separate payment shall be made for cores drilled as
part of the contractor's obligations under process control, the cost of which shall be included in the
prices tendered for the various items of asphaltic paving
The tendered rate shall include full compensation for drilling the cores as directed, for all plant, fuel,
labour and other incidentals necessary and for refilling the core hole with an approved mix and
compacting the mix as specified.

Item 64.09 Asphalt overlays constructed for rehabilitation purposes in accordance with the
provisions of sub-clause 6414(f)
(a) Base constructed with new asphaltic mix (state thickness, type of bitumen and maximum size
of aggregate)
2
(i) Continuously graded ................................................................... square metre (m )
2
(ii) Gap graded ................................................................................. square metre (m )
(b) Surfacing or overlay constructed with new asphaltic mix (state thickness, type of bitumen and
maximum size of aggregate)
2
(i) Continuously graded ................................................................... square metre (m )
2
(ii) Gap graded ................................................................................. square metre (m )
(c) Base constructed with recycled asphaltic mix (state thickness, type of bitumen and maximum
2
size of aggregate) ..................................................................................... square metre (m )
(d) Surfacing or overlay constructed with recycled asphaltic mix (state thickness, type of bitumen
2
and maximum size of aggregate) ............................................................. square metre (m )
The unit of measurement for sub-items (a) and (b) shall be a square metre of asphaltic base, surfacing
or overlay constructed to the specified thickness. The quantity shall be calculated from the authorized
dimensions.
The unit of measurement for sub-items (c) and (d) shall be a square metre of asphaltic base, surfacing
or overlay constructed with recycled asphalt consisting of recovered asphalt and new materials mixed
in the prescribed ratio. The quantity shall be calculated from the authorized dimensions.
The tendered rate for sub-items (a) and (b) shall include full compensation for procuring, providing,
heating, mixing, transporting, placing and compacting the material; process control tests; and
protection and maintenance; all complete as specified. Rolled-in chippings will be paid for separately
under item 64.03, and the additional cost for applying rolled-in chippings in restricted areas will be paid
for under item 64.15.
The tendered rate for sub-items (c) and (d) shall include full compensation for supplying the new
materials, taking recovered asphalt from stockpile, blending the materials in accordance with the
nominal mix ratios specified in the project specifications, heating, mixing, placing and compacting the
material, process control tests, and protection and maintenance, all complete as specified. Payment
will distinguish between different types of recycled asphaltic mix in accordance with the project
specifications. No extra payment will be made for small quantities of recycled asphalt.
Item 64.10 Asphalt overlays constructed for rehabilitation purposes in accordance with the
provisions of sub-clauses 6414(f)
(a) Base constructed with new asphaltic mix (state thickness, type of bitumen and maximum size
of aggregate)
(i) Continuously graded ...................................................................................tonne (t)
(ii) Gap graded .................................................................................................tonne (t)
(b) Surfacing or overlay constructed with new asphaltic mix (state thickness, type of bitumen and
maximum size of aggregate)
(i) Continuously graded ...................................................................................tonne (t)
(ii) Gap graded .................................................................................................tonne (t)

(c) Base constructed with recycled asphaltic mix (state thickness, type of bitumen and maximum
size of aggregate) .................................................................................................... tonne (t)
(d) Surfacing or overlay constructed with recycled asphaltic mix (state thickness, type of bitumen
and maximum size of aggregate) ............................................................................ tonne (t)
The unit of measurement for sub-items (a) and (b) shall be a tonne of asphalt placed. The quantity
shall be determined by means of certified weighbridge tickets issued in respect of the asphalt mix
used. No payment will be made for asphalt placed outside the tolerances specified.
The unit of measurement for sub-items (c) and (d) shall be a tonne of recycled asphalt consisting of
recovered asphalt and new materials mixed in the prescribed ratio. The quantity shall be determined
by means of certified weighbridge tickets issued in respect of the asphalt mix used. No payment will be
made for asphalt placed outside the tolerances specified.
The tendered rate for sub-items (a) and (b) shall include full compensation for procuring, providing,
heating, mixing, placing and compacting the material, process control tests, and protection and
maintenance, all complete as specified. Rolled-in chippings will be paid for separately under item
64.03, and the additional cost for applying rolled-in chippings in restricted areas will be paid for under
item 64.15.
The tendered rate for sub-items (c) and (d) shall include full compensation for supplying the new
materials, taking recovered asphalt from stockpile, blending the materials in accordance with the
nominal mix ratios specified in the project specifications, heating, mixing, placing and compacting the
material, process control tests, and protection and maintenance, all complete as specified.
Payment will distinguish between different types of recycled asphalt in accordance with the project
specifications. No extra payment will be made for small quantities of recycled asphalt.
Item 64.11 Extra over items 64.01, 64.02, 64.09 and 64.10 for placing small quantities of
asphaltic mixes of less than 10 tons, specially produced as specified in sub-
clause 6407(d) ............................................................................................. tonne (t)
The unit of measurement shall be a tonne of asphalt of a specified composition, less than 10 tonnes of
which is produced on occasion, as specified, and measured in accordance with the certified
weighbridge tickets issued in regard to the mix used.
The tendered rate shall be paid as extra over the rates tendered for the items mentioned above, and
shall include full compensation for all additional costs to produce and place small quantities of asphalt
on the instruction of the Engineer.
Payment will not distinguish between various types of asphalt or various types of asphalt layers.
Item 64.12 Placing and compacting asphaltic mixes in restricted areas:

2
(a) Extra over items 64.01, 64.02 and 64.09 .................................................square metre (m )
(b) Extra over item 64.10 .............................................................................................. tonne (t)
The unit of measurement shall be a square metre or a tonne of asphalt (in accordance with the unit of
measurement for the item concerned), placed in restricted areas, the quantity of which shall be
measured as specified for the item of payment concerned.
The tendered rates shall include full compensation for additional costs for executing the work in
restricted areas.

Item 64.13 Extra over item 64.04 for applying tack coat in restricted areas ...............litre (ℓ)
The unit of measurement shall be a litre of 30% stable-grade emulsion applied in restricted areas.
The tendered rate shall include full compensation for additional costs for applying the tack coat in
restricted areas, irrespective of the method of application.
Item 64.14 Application of prime coat and/or tack coat to the edges of a layer ...........litre (ℓ)
The unit of measurement shall be a litre of 30% stable-grade emulsion tack coat or MC 30 prime
applied to the edge of a layer against which asphalt has to be placed.
The tendered rate shall include full compensation for obtaining, procuring and applying the material,
irrespective of the layer thickness, the method of application, or the size of the area over which it has
to be applied.
Item 64.15 Extra over item 64.03 for applying rolled-in chippings in restricted areas .........
........................................................................................................................tonne (t)
The unit of measurement shall be a tonne of rolled-in chippings applied in restricted areas at the
specified rate.
The tendered rate shall include full compensation for the additional cost for executing the work in
restricted areas.
2
Item 64.16 Asphalt reinforcing complete (state type) .................................. square metre (m )
The unit of measurement shall be a square metre of asphalt covered with reinforcing placed. complete
as specified and accepted by the Engineer.
The tendered rate shall include full compensation for procuring, providing, placing and fixing all
materials (irrespective of the quantity of reinforcing required) overlapping and cut-offs included, and for
all transport, equipment, tools, labour, supervision and all other costs necessary for installing and
protecting the reinforcing until the asphalt prime coat has been placed. The tendered rate shall also
include full compensation for all special preparatory work required. If it is necessary to repair cracks in
the underlying seal or asphalt layer, separate payment will be made therefore under the appropriate
items of payment.
Item 64.17 Variations from nominal mix ratios in recycled asphaltic mixes
(a) New binder (state penetration-grade of bitumen) .....................................................tonne (t)
(b) New aggregate ........................................................................................................tonne (t)
(c) New active mineral filler ...........................................................................................tonne (t)
The unit of measurement for an increase or decrease in the content of new binder, aggregate or
mineral filler in the recycled asphalt mixture, in relation to the content specified in the nominal mixture
(See sub-clause 6403(c)), shall be a tonne of binder, aggregate or filler.
Where payment for recycled asphalt is per square metre, the varied quantity shall be calculated by
converting volume to mass using the average density of the asphalt layer measured after compaction.
Payment for variations shall be made in accordance with the provisions of sub-clause 0103(g).
Payment will not be made for an increase in the quantity of new material required where this results
from recovered asphalt being wasted. The contractor is warned that the quantity of recovered material
available for recycling will be determined in accordance with the authorized quantities excavated, and
the tendered rates shall include full compensation for making good losses in recovered materials.

Item 64.18 Variations in cellulose fibre content of stone mastic asphaltic mixes ................
....................................................................................................................... tonne (t)
The unit of measurement for an increase or a decrease in the cellulose fibre content of stone-mastic
asphaltic mixes in comparison with the specified nominal cellulose fibre content approved as part of
the design process (see Sub-Clause 6403(a)(v)) shall be a tonne of cellulose fibres.
Payment for variations shall be made in accordance with the provisions of sub-clause 0103(g).
Item 64.19 Backfilling of excavations for patching with :

(a) Asphaltic base ......................................................................................................... tonne (t)
(b) Asphaltic surfacing ................................................................................................... tonne (t)
The unit of measurement shall be a tonne of asphalt placed in accordance with the specified
requirements. The quantity will be computed in accordance with the certified weighbridge tickets
issued in respect of the asphalt mix. Payment will not be made for wasted material.
The tendered rate shall include full compensation for procuring and providing all materials, irrespective
of its origin for all mixing placing, compacting and finishing as specified, for all transport, work in
restricted areas, and also for all machinery, equipment, labour, supervision and, other incidentals for
executing the work, complete as specified.
Payment for asphalt base and surfacing will not distinguish between the various types of asphalt.
Item 64.11, for small quantities of asphalt, shall not apply to patching
Screeds, where required, shall be measured and paid for under item 66.04

Division 6500: Surfacing of Bridge Decks
6501 Scope
This section covers the construction of a hot, pre-mixed bituminous surfacing (as specified in Division
6400) on bridge decks where shown on the Drawings or ordered by the Engineer.
The provisions of Division 6400 "Bituminous Road Bases and Surfacings" apply equally to the work
covered by this Division and will not necessarily be repeated or specifically referred to in this Division.
6502 Materials
Bituminous binders and aggregate shall comply with the requirements of Division 6400 for hot, pre-
mixed bituminous surfacing and Division 6300 for other bituminous surface treatments and seals.
6503 Preparation of Surface

Before the surfacing is constructed, the concrete deck shall be thoroughly cleaned by washing and
brushing to remove all loose material. After drying, a tack coat as specified in Division 6200 shall be
applied to the surface.
6504 Type and Thickness of Surfacing

The type and nominal thickness of the surfacing shall be as indicated on the Drawings and/or specified
in the Particular Specifications.
Before commencing with the construction of the surfacing, an accurate survey of the actual levels of
the bridge deck shall be made. The levels and grades to which the surfacing is to be constructed shall
be as shown on the Drawings or as indicated by the Engineer.
If the levels of the concrete deck, as constructed by the Contractor, deviate by more than the specified
tolerances from the specified levels, the Contractor shall construct a levelling layer at his own cost.
The nominal size of the aggregate in the levelling layer shall be 9.5 mm.
6505 Construction
Irrespective of the type of surfacing on the road on both sides of the bridge, hot, pre-mixed bituminous
surfacing for bridge decks shall be constructed in accordance with Division 6400, and surface seals for
bridge decks in accordance with Divisions 6300.
6506 Surface Tolerances

The completed surfacing shall comply with the requirements of Clauses 6313 and 6414 in respect of
surface tolerances for grade, smoothness, cross section and width related to the specific surfacing
type.

Item 65.01 Asphalt surfacing on bridge deck (state type and thickness)
(a) Continuously graded (state grade) ........................................................... square metre (m²)
(b) Gap-graded (state stone content) ............................................................ square metre (m²)
(c) Open-graded (state grade) ....................................................................... square metre (m²)

(d) Stone-mastic asphaltic (state maximum size of aggregate) ..................... square metre (m²)
(e) Dense Bitumen Macadam ........................................................................ square metre (m²)
The unit of measurement shall be the square metre of asphaltic surfacing constructed to the thickness
specified. When specified in the Particular Specifications and/or indicated in the Bill of Quantities, the
unit of measurement shall be the tonne of asphalt constructed as specified and measured according to
certified weighbridge tickets issued in respect of mixture used. In the case of resurfacing using
asphaltic mixes, measurement by tonne shall be obligatory. No payment will be made for material
wasted.
The tendered rate shall include full compensation for procuring and furnishing all materials, heating the
binder and aggregate, mixing, transporting, placing and compacting the material, and the provision
and application of the slurry. The rate shall also include full compensation for variations in thickness
within the specified tolerance for bridge deck levels.
3
Item 65.02 Rolled-in chippings (nominal size indicated) in surfacing ........ cubic metre (m )
The unit of measurement shall be the cubic metre of rolled-in chippings applied at the specified rate,
measured loose in hauling vehicles.
The tendered rate shall include full compensation for the procuring, furnishing, pre-coating,
transporting, spreading and rolling in of pre-coated chippings and for any additional costs resulting
from more difficult construction of the asphalt surfacing with rolled-in chippings.

Division 6600: Treatment of Certain Defects in Existing Bituminous

Surfacing
6601 Scope
This Division covers the work in connection with the treatment of defects of bituminous surfacings of
existing road surfaces. It covers the treatment of existing surfacings where:
 The existing surface is deficient in binder.

 Marked differences in texture occur over the surface.
 The existing surface is open-textured.
 The surface is uneven on account of bumps, slacks, etc.
 Edges require trimming and/or repairs
It also covers planing of the road surface, fog spraying, texturing, slurry sealing, screeding, sealing
cracks and building up broken edges with bituminous concrete.
The provisions of Division 6300 and 6400 apply equally to the work covered by this Division and will
not necessarily be repeated or specifically referred to in this Division.
6602 Materials
(a) Bituminous binders

Unless otherwise specified in the Particular Specifications or the Bill of Quantities, or directed by the
Engineer, the following types and grades of binder shall be used:
Bituminous binders shall comply with the appropriate requirements of Divisions 6300, Division 6400 or
as specified herein.
(i) Primer for sealing cracks

Invert bitumen emulsion as specified in Division 6100 shall be used.
(ii) Binders for crack treatment

nd
Anionic stable-grade bitumen emulsion shall be used or modified binders (based on TG1, 2 edition,
2007 from SABITA) for the following generic homogenous and non-homogenous modified binder
classes for crack sealing material:
 C-E1 Crack sealant – hot applied elastomer modified

 CC-E1 Crack sealant – emulsion elastomer modified
 C-R1 Crack sealant – hot applied bitumen rubber
The property requirements of the modified crack sealant classes are shown in Table 6602/1.
Table 6602/1: Property requirements for modified crack sealants
Test method Class

Property Unit
(TG1, 2nd edition, 2007) C-E1 CC-E1 C-R1
1
Softening Point ºC MB-17 ≥ 80 ≥ 80 55 - 65
1
Elastic Recovery @ 15ºC % MB-4 ≥ 80 ≥ 60 -
Dynamic Viscosity @ 190ºC dPa.s MB-13 - - 20 - 40
Dynamic Viscosity @ 165ºC Pa.s MB-18 ≤ 0.65 - -
Dynamic Viscosity @ 25ºC Pa.s MB-18 - ≤ 0.8 -
Resilience @ 25ºC % MB-10 - - 13 - 40
Flow mm MB-12 - - 15 - 70
Binder content (m/m) % MB-22 - ≥ 55 -
1
Values to be determined on the residue after recovery of the binder by evaporation method MB-20

Rubber crumbs used for crack sealing for C-R1 material shall be obtained by processing rubber tyres
and conform to the requirements of sub-clause 6303(a)(vi).
(iii) Fog spray

30%, 40%, 50% or 60% cationic or anionic spray-grade or stable-grade emulsion shall be used in
accordance with the requirements.
(iv) Tack coat for texturing

60% anionic or cationic spray-grade emulsion shall be used.
(v) Slurry-seal
Tack coat: 30% stable-grade emulsion
Slurry seal: 60% slurry-grade emulsion
(vi) Screed
Tack coat: 30% bitumen emulsion;
Bituminous concrete: 80/100 penetration-grade bitumen.
(vii) Binder in asphalt for patching

Tack coat: 60% stable-grade emulsion
Bituminous concrete: 80/100 penetration-grade bitumen
(b) Herbicides
Herbicides used for the control of vegetation shall be a non-selective herbicide approved by the
Engineer and should not be detrimental to existing bituminous surfacings.
(a) Planing machine

The machine shall be of a design, which will be suitable for planing the existing surfacing in order to
remove any irregularities and to leave an even surface without tearing the underlying material. An
approved milling machine may be used.
Before planing may start, the Contractor shall demonstrate to the Engineer that the machine is in fact
capable of executing the work in accordance with the specifications.
(b) Equipment for crack-sealing

In addition to the equipment normally used for surface treatments, the following equipment will be
necessary for the sealing of cracks:
 A double vibratory roller having a mass of 0.75 tonne or similar, with an adjustable amplitude
and frequency of vibration;
 A mobile compressor capable of producing at least 3 m3/min at 750 kPa for blowing out
cracks;
 Special spraying equipment with 2 mm nozzle openings;
 Special heating equipment where appropriate for cleaning cracks; and
 Custom-built applicators for applying sealants to cracks.
(c) Other equipment

All equipment shall be suitable for the specified use and working areas and shall be capable of
obtaining the specified results.

6604 Construction
Before any treatment is carried out, the area to be treated shall be cleaned and prepared as specified
in sub-clause 6305(k), and any major failures shall be repaired as specified in this section and in the
(a) Treatment with diluted bituminous emulsion (fog spray)

This treatment will be applied where in the opinion of the Engineer the existing surface is deficient in
binder.
The treatment shall consist of the application of a fog spray of the specified grade of bituminous
emulsion to the existing surface by means of a pressure distributor at the rates of application as
directed by the Engineer, in widths that may vary from 0.5 m to 4.0 m. A 30%, 40%, 50% or 60%
cationic or anionic spray grade emulsion, as specified, shall be used.
(b) Texturing
A tack coat of cut-back bitumen or the specified type and grade of emulsion shall be applied to the
surface as specified in sub-clause 6207, or 80/100 or 150/200 penetration grade bitumen, followed by
an application of clean crusher sand. The crusher sand shall be the medium grade specified for slurry
in Table 6303/15, but shall be on the coarse side of the grading envelope, and shall be subject to the
Engineer's approval.
The nominal rates of application shall be:

2
 80/100 or 150/200 penetration-grade bitumen: 0.70 l/m (net bitumen);
2
 Cut-back bitumen: 0.70 l/m (net bitumen)
2
 Emulsion: 0.70 l/m (net bitumen)
3 2
 Aggregate. 0.0045 m /m
The actual rates of application shall be as instructed by the Engineer.
It is anticipated that spraying and spreading may have to be carried out in narrow strips varying in
width from 0.5 m to 2.0 m. The emulsion shall be allowed to break before the aggregate is applied.
As soon as the aggregate has been spread, patches where it has not been spread evenly shall be
corrected by brooming the patch with a hand broom or a light drag broom.
Rolling shall be done as specified in sub-clause 6304(g). Any excess aggregate remaining on the road
after it has been opened to traffic for two (2) days or more shall be removed.
This treatment, or a sand seal as specified in Clause 6319, is intended for application where marked
differences in texture occur in the existing surfacing, in order to obtain a uniform texture before
resealing.
(c) Slurry texture treatment

Slurry seal shall comply with the requirements of Clauses 6304(g) and 6318. This treatment shall be
used when an existing surface treatment, which is open-textured, requires treatment with bituminous
slurry.
Prior to treatment with a slurry, the surface shall be sprayed with a tack coat of 30% bitumen emulsion
of the type and at the rate prescribed by the Engineer.
A distinction shall be made in respect of payment for the following two methods of construction:
 Where the slurry can be applied by hand methods only; or where the Engineer so directs; or
where it is specified that the slurry shall be applied by hand methods.
 Where the slurry can be applied mechanically with a spreader box.
The slurry shall be prepared, mixed and applied as specified in Clauses 6318, except that slurry to be
applied by hand can be mixed in a suitable concrete mixer and worked into cracks or other open
patches with brooms or squeegees until the surface is smooth and even; and where a spreader box is
used for applying the slurry, it shall be applied in one layer.
3 2
A nominal rate of application of 0.004m /m shall apply for tender purposes.
(d) Screed
This treatment is used where the road surface is uneven and where depressions, humps or small
grooves occur, which, in the opinion of the Engineer, are the result of the deformation of the pavement
layers, but not attributed to the structural failure of the pavement.
Where both planing and screeding are specified, the screed shall be placed after the planing has been
completed.
Where milling is required, it shall be done in accordance with the requirements of Division 5300.
The existing surface shall be swept clean or cleaned by other approved methods of dust, soil, gravel,
loose stones or any other undesirable material. A tack coat of 30% anionic stable-grade emulsion shall
then be applied at a rate prescribed by the Engineer.
The bituminous material used for the screed shall be hot mix asphalt or coarse slurry as specified in
the Particular Specifications.
Where the surface of the screed breaks up, a slurry-seal treatment shall be applied in accordance with
sub-clause (c) of this Clause, or the screed shall be removed and replaced, all at the cost of the
Contractor.
(i) Asphalt Concrete or Hot Mix Asphalt

AC or HMA used as a screed shall consist of a medium or fine-grade continuously graded mix,
proportioned as specified in Table 6403/3. The actual grade of the mix used shall be in accordance
with the instruction of the Engineer or as determined by the required thickness of the screed.
The asphalt material shall be produced, transported, placed and compacted as specified in Division
6400, as applicable. The paver shall be so adjusted that the straight-edge blade will screed off high
spots on the existing surface and the material will therefore be placed only in depressions. Where high
spots have been planed down, the straight- edge blade shall operate over the planed surface. The
screed shall nevertheless comply with the specified standards for evenness. Where the required
bituminous concrete thickness exceeds 25 mm at any position, such sections of the screed shall be
placed in more than one layer if so instructed by the Engineer. Such layer thicknesses shall be in
accordance with the instructions of the Engineer.
(ii) Coarse slurry

The aggregate for coarse slurry shall comply with the requirements for coarse grading in sub-clause
6304(g). The slurry shall be prepared and applied in accordance with the requirements of Clauses
6304(g) and 6318.
(iii) Requirements for evenness

When a completed screed surface is tested, it shall not deviate by more than 6 mm from the bottom
edge of a 3 metre straight-edge placed in any direction.
(e) Repairing edge breaks in surfacing

This treatment shall be used for restoring the road edges to the true edge lines of the original road or
to such other edge line as may be required.
The existing surfacing shall be cut back and the pavement material shall be excavated as specified in
Clause 5305.
Where the surfacing, after having been cut back, requires building up to bring it to the required width,
the surface so exposed shall be swept clean, watered, and if so instructed, compacted. It shall then be
tack coated as specified in Division 6200. The edges shall then be built up with medium continuously-
graded asphalt concrete in accordance with Table 6403/3. The built-up edges shall be properly
compacted and finished in accordance with the required lines and levels.
(f) Sealing cracks
(i) General
The types of cracks treated will be specified in the Particular Specifications or the Bill of Quantities.
The Engineer will instruct the Contractor regarding the type of treatment to be used in the various
cases.
(ii) Preparation
The cracks shall be blown clean with compressed air, and all foreign and loose matter shall be
removed from the cracks.
A supply of approved herbicide diluted in accordance with the requirements of the Particular
Specifications or the Bill of Quantities shall be prepared. The solution shall be sprayed into cracks on
the surfaced shoulders of the road or on such extended area as specified in the Particular
Specifications by means of rucksack type of sprayers, and allowed to dry.
Twenty-four (24) hours after application of the herbicide, the cracks shall be penetrated with a suitable
prime in accordance with Division 6100, as instructed by the Engineer.
(iii) Cracks smaller than 3 mm

Cracks smaller than 3 mm shall be sealed with an emulsion; or treated by resealing the surface.
(iv) Cracks of 3 mm and wider

After the prime has been applied, a suitable modified homogenous or non-homogenous crack sealant
as specified in the Particular Specifications or the Bill of Quantities and meeting the generic
requirements of Table 6602/1 shall be applied by means of pneumatic spraying equipment or other
approved equipment sufficient to fill the cracks.
Where the cracks are to be rolled, the Contractor, in accordance with the provisions of the Particular
Specifications or the instruction of the Engineer, shall treat the cracks by heating in an approved
manner along the full length of the crack and over a width of 250 mm on each side of the crack and
then roll with approved rollers until an even surface has been obtained.
Where, in the opinion of the Engineer, the cracks are too wide for this type of treatment, the Contractor
shall treat the cracks in accordance with the instructions of the Engineer.
(v) Other sealants

Other approved sealants shall comply with and be applied in accordance with the requirements of the
(vi) Restrictions
Cracks may be sealed only where the temperature of the road surface exceeds 10°C. Crack sealing
may not be done within 3 days after rain has fallen on the site, unless otherwise instructed by the
Engineer.
The Contractor shall note that a single application of crack sealant is usually insufficient and that the
application will have to be repeated.

(g) Pre-treatment of the road surface by means of planing

Planing shall be done with an approved planing or milling machine. The areas of the road to be planed
shall be as directed by the Engineer and may include limited sections or the entire width of the
surface. The work shall involve the planing high spots or ridges in the existing asphalt surfacing in
accordance with specified level requirements.
The planed surface shall be even without any ridges or steps between the longitudinal cuts. Where
planing is required over a portion of the road width, the edge of the planed section shall be vertical and
straight. The planed surface shall be suitable for immediate opening to traffic if so required by the
Engineer.
Material planed off shall be transported to stockpiles for recycling, or to spoil dumps, whichever is
required.
Material removed beyond the specified limits shall be replaced by the Contractor at his own cost and
to the satisfaction of the Engineer.
After planing has been completed, depressions over which the planing machine has moved without
touching the surface, and which fall outside the specified smoothness requirements, shall be filled in
as specified, or, if so instructed by the Engineer, a screed shall be placed as specified in sub-clause
6604(d).
Payment will be made only for filling in depressions which existed in the original surface. Depressions
formed as a result of the activities of the Contractor shall be filled in at his own cost.
Upon completion, the entire treated surface, or where depressions have not been filled in then the
planed surface, shall be tested for shape, and, unless otherwise specified in the Particular
Specifications, the surface shall not deviate by more than 6 mm when tested using a 3 metre straight-
edge placed in any direction.
(i) Fog spraying of planed surfaces

After the planing operation has been completed, the planed surface or, if so directed by the Engineer,
the entire levelled surface, shall be sprayed with a 30% spray-grade emulsion, which may be further
diluted if necessary, in accordance with the instructions of the Engineer, at a rate of application to be
determined by the Engineer. The surface shall then be rolled with approved pneumatic rollers until it
has dried off sufficiently and, in the opinion of the Engineer, can be opened to traffic.

The opening of the road to traffic shall be subject to the requirements of Clause 6309.
The road shall be left open to traffic for such period as the Engineer may direct before further surface
treatment work is carried out.

Item 66.01 Treatment with diluted bituminous emulsion (fog spray)

(a) 30% bitumen emulsion ............................................................................................... litre (ℓ)
(b) 40% bitumen emulsion ............................................................................................... litre (ℓ)
(c) 50% bitumen emulsion ............................................................................................... litre (ℓ)
(d) 60% bitumen emulsion ............................................................................................... litre (ℓ)

The unit of measurement for treatment with diluted bituminous emulsion (fog spray) shall be the litre of
bituminous emulsion sprayed; and measured at spraying temperature.
The tendered rates shall include full compensation for cleaning and preparing the existing surface, for
furnishing the material and applying the fog spray and for all other incidentals necessary for
completing the work as specified.
Item 66.02 Texturing

(a) Tack coat (state type of binder) ...................................................................................litre (ℓ)
3
(b) Application of slurry seal with double-washed aggregate ..........................cubic metre (m )
The unit of measurement for binder application for the tack coat shall be the litre of net bitumen cold.
The unit of measurement for the slurry seal with double-washed aggregate shall be the cubic metre of
aggregate applied, measured loose in the truck and corrected for bulking as described in item 63.17.
The tendered rates shall include full compensation for furnishing all materials, demarcating the areas
to be sprayed, spraying the binder and applying the aggregate. rolling, sweeping and all other
incidentals necessary for completing the work as specified.
Item 66.03 Slurry seal

(a) Tack coat using 30% bitumen emulsion (state rate of application) .............................litre (ℓ)
3
(b) Slurry applied by hand ..................................................................................cubic metre(m )
3
(c) Slurry applied by spreader box ...................................................................cubic metre (m )
(d) Slurry applied by hand .............................................................................................tonne (t)
(e) Slurry applied by spreader box ................................................................................tonne (t)
The unit of measurement for tack coat shall be the litre of emulsion measured at spraying temperature
and applied as specified.
The unit of measurement for slurry shall be the cubic metre of saturated fine aggregate used, and
measured as described in pay item 63.17, or the tonne of saturated fine aggregate used, as specified.
The tendered rates shall include full compensation for procuring and furnishing all the materials, for
mixing and applying the slurry, demarcating all areas to be treated and for all plant, labour and
incidentals necessary to complete the work as specified.
Item 66.04 Screed of asphalt concrete or coarse slurry:

(a) Tack coat using 30% stable-grade bitumen emulsion .................................................litre (ℓ)
(b) Continuously-graded AC (state nominal aggregate size) ........................................tonne (t)

3
(c) Coarse grade slurry ....................................................................................cubic metre (m )
The unit of measurement for the tack coat shall be the litre of emulsion applied, measured at spraying
temperature.
The unit of measurement for AC shall be the tonne of material placed according to the specifications.
The unit of measurement for coarse grade slurry shall be the cubic metre of aggregate mix used in the
slurry.
The tendered rate for tack coat shall include full compensation for procuring, furnishing and applying
the tack coat and demarcating the areas to be sprayed and for all incidentals necessary for completing
the work as specified.

The tendered rate for AC shall include full compensation for procuring, furnishing and mixing all the
materials; for placing the material and for all transport and other incidentals necessary to complete the
work as specified.
The tendered rate for slurry shall include full compensation for all materials, equipment and labour for
producing and applying the slurry, irrespective of the number of applications required to attain the
required thickness.
Item 66.05 Repairing edge breaks in surfacing:

(a) Tack coat using 30% bitumen emulsion ..................................................................... litre (ℓ)
(state rate of application)
(b) Reconstructing edges using continuously-graded AC ............................................. tonne (t)
(state nominal aggregate size)
The unit of measurement for the tack coat shall be the litre of specified emulsion applied as specified
and measured at spraying temperature.
The unit of measurement for reconstructing pavement edges shall be the tonne of continuously-
graded AC furnished and compacted as specified.
The tendered rate for reconstructing pavement edges shall include full compensation for compacting
the surface on which the new edge is to be constructed and procuring, furnishing and mixing all
materials and placing, compacting and trimming the bituminous concrete to the required lines and
levels It shall also include full compensation for applying a tack coat of emulsion to the surface to be
treated.
The tendered rates shall include full compensation for all transport, handling, labour, material and all
incidentals necessary to complete all the work, as specified.
Item 66.06 Cleaning the cracks with compressed air. ...................................... kilometre (km)
The unit of measurement for cleaning the cracks with compressed air shall be a kilometre of road
along which all the cracks have been blown clean.
The tendered rate shall include full compensation for providing all equipment, labour, supervision and
incidentals for blowing clean the cracks over the full width of the road to the satisfaction of the
Engineer.
Item 66.07 Applying bituminous binders and herbicides for sealing cracks:
(a) Herbicide ..................................................................................................................... litre (ℓ)
(b) Prime .......................................................................................................................... litre (ℓ)
(c) Anionic stable-grade emulsion ................................................................................... litre (ℓ)
(d) Modified Crack sealant (state type as classified in sub-clause 6602(a)).................... litre (ℓ)
(e) Other specified agents (type indicated) ..................................................................... litre (ℓ)
The unit of measurement shall be a litre of material applied as specified or as instructed by the
Engineer.
The tendered rates shall include full compensation for providing, mixing, heating (where required) and
applying all the materials as specified, and for all equipment, labour, supervision and incidentals for

completing the work. No additional payment will be made for multiple applications of material, and
payment will not distinguish between the various types, widths or lengths of cracks.
Item 66.08 Rolling the cracks .................................................................................... metre (m)

The unit of measurement shall be a metre of crack rolled to the satisfaction of the Engineer.
The tendered rate shall include full compensation for rolling the cracks complete as specified.
2
Item 66.09 Planing ......................................................................................... square metre (m )
The unit of measurement shall be a net square metre of road surface planed in accordance with the
specifications.
The tendered rate shall include full compensation for planing; for obtaining the required surface
regularity to a maximum depth of 25 mm; collecting, loading and removing the planed material; for all
plant movement over the site as instructed by the Engineer; and for providing planing and other
equipment, labour, supervision and incidentals for completing the work in accordance with the
specifications; including filling up irregularities caused by the contractor. Any planing of deeper than
25 mm will be classified as milling.
Item 66.10 Fog spraying on planed surfaces:

(a) Hand spraying ............................................................................................................litre (ℓ)
(b) Spraying with mechanical equipment .........................................................................litre (ℓ)
The unit of measurement shall be a litre of 30% spray-grade emulsion sprayed on planed surfaces on
the instruction of the Engineer.
The tendered rate shall include full compensation for fog spraying on planed surfaces complete as
specified.
2
Item 66.11 Rolling planed surfaces ........................... square metre of roller passes (m -pass)
The unit of measurement shall be a square metre of roller-pass with an approved pneumatic roller on
planed surfaces as may be directed by the Engineer.
The tendered rate shall include full compensation for the rolling of planed surfaces complete as
specified.
Item 66.12 Filling depressions in planed surfaces with AC ......................................tonne (t)

The unit of measurement shall be a tonne of AC, of the specified composition, placed in depressions in
planed surfaces measured in accordance with certified weighbridge tickets The tendered rate shall
include full compensation for the filling of depressions in planed surfaces complete as specified.
No extra payment will be made for small quantities of AC.
Where a screed is placed, payment will be made under item 66.04.

Division 6700: Bituminous Road-Mix Surfacing
6701 Scope
This work shall consist of aggregate and bituminous material mixed in-place on a prepared surface
and constructed in accordance with these Specifications and in conformity with the lines, grades, and
typical cross section shown on the Drawings. Aggregate shall consist of either new aggregate
(Case 1), or aggregate present in the existing road (Case 2), whichever is called for in the Particular
Specifications.
The percentage of bituminous material, by weight, to be added to the aggregate will usually be
between 3.5 and 7 per cent of the weight of the dry aggregate. The exact percentage to be used shall
be fixed by the Engineer based on preliminary laboratory tests and field sieve analyses of the
aggregates furnished or in place.
6702 Materials
(a) New Aggregate (Case 1)

New aggregate (Case 1) shall consist of coarse aggregate of crushed gravel, crushed boulder, or
crushed rock, composed of hard, durable particles and a filler of finely crushed stone, sand, or other
finely divided mineral matter. The portion of the material retained on a 5 mm sieve shall be known as
coarse aggregate, and that portion passing a 5 mm sieve shall be known as fine aggregate. The total
mineral aggregate shall be graded within one of the gradations shown in Table 6702/1, whichever is
called for in the Particular Specifications, when tested in accordance to AASHO T 11 and T 27.
Table 6702/1: Grading Requirements for Road Mix Bituminous Surface Courses
Sieve Size Percentage passing (by weight)

(mm) A B C D
28 100 100 - -
20 85-100 75-100 100 -
14 - - 40-65 100
5 45-65 30-60 25-50 50-70
2 30-50 20-50 12-40 30-50
0.425 10-25 - 3-20 -
0.075 3-10 3-10 0-10 3-10
If crushed gravel is used, not less than 50 per cent by weight of the coarse aggregate particles
retained on the 5 mm sieve shall be particles having at least one fractured face.
The coarse aggregate shall have a percentage of wear of not more than 40 at 500 revolutions, as
determined by AASHTO T 96. That portion of the aggregate passing a 5 mm sieve shall have a
plasticity index of not more than 6, as determined by AASHO T 90 or a liquid limit not greater than 30,
as determined by AASHTO T 89.
The fine aggregate shall be in accordance with AASHTO M 29, and the mineral filler in accordance
with AASHTO M 17.
The material shall be free from clay balls and adherent films of clay or other matter that would prevent
thorough coating with bituminous material.
(b) Aggregate from the Existing Surface (Case 2)

Where aggregate required for the road-mix surface course is already in place, the Contractor shall not
be responsible for its grading or quality except for removal of oversize pieces. In general, salvaged
aggregate to be used for road-mix surface course will consist of material meeting the requirements
given above for new aggregate or may consist of selected granular material of other gradings. Any
particles of salvaged aggregate appearing in the surface at the time of lay-down and finishing that will
not pass a 37.5 mm sieve shall be removed by the Contractor as directed by the Engineer.
(c) Bituminous Materials

Bituminous materials shall be cutback bitumen as specified in SANS 4001-BT2 of the grade MC 250
or MC 800 or cationic premix emulsion (60% or 65%) as specified in Table 6303/3 and called for in the
6703 Equipment
The equipment used by the Contractor shall include scarifying, mixing, spreading, finishing, and
compacting equipment, a self-powered bituminous material distributor, and equipment for heating
bituminous material.
The pressure distributor shall be equipped with pneumatic tyres and shall be so designed and
operated as to distribute the bituminous material in a uniform spray without atomisation, in the amount
and between the limits of temperature specified. It shall be equipped with a fifth wheel speedometer
registering in metres per minute and so located as to be readable by the truck driver. The distributor
pump shall be motor-driven and shall be equipped with an accurate metering device registering litres
per minute passing through the nozzles, which shall be so located as to be readable by the operator. A
thermometer well shall be so placed in the distributor tank as not to be in contact with a heating tube.
Suitable means for accurately indicating at all times the temperature of the bituminous material shall
be provided. The distributor spray bar shall be adjustable, both for height and for the normal width of
application (3.5 metres) or less with a hand spray attachment. The distributor heating attachments
shall be so equipped and operated that the bituminous material shall be circulated or agitated
throughout the entire heating process.
Rollers for compacting the surface shall be self-powered tandem or 3-wheel rollers weighting between
5 and 8 tonnes and having a minimum weight of thirty-six (36) kg/cm. of rear wheel width, or a
pneumatic tyred roller with tyre pressures in the range of 5-9 kg/cm².
Either travelling or stationary mixing plants or other equipment of proven performance may be used by
the Contractor in lieu of the specified equipment if the Contractor complies with such requirements as
the Engineer may consider necessary to ensure results that shall be at least equal to results which
would be obtained by use of the specified equipment.
6704 Construction
(a) Weather Limitations

Bituminous material shall be applied to the aggregate when the atmospheric temperature in the shade
is above 10°C and rising or above 15°C if falling; when the weather is not foggy or rainy; and when the
moisture content of the aggregate conforms to the requirements in sub-clause 6704(e).
(b) Preparation of Road base and New Aggregate (Case 1)

When new aggregate is to be used for the road-mix surface course, the existing road base shall be
scarified lightly and bladed to uniform grade and to the cross section shown on the Drawings and shall
then be rolled, or watered and rolled, as directed. If so ordered by the Engineer, depressions shall first
be filled and weak portions of the road base strengthened with new aggregate.
New aggregate shall be uniformly spread on the road by the use of spreader boxes, or other approved
mechanical spreading devices. It shall then be windrowed. The aggregate shall be so deposited that
each windrow will be of uniform section and will contain the correct quantity of aggregate to provide
surfacing of the required width and thickness.
(c) Preparation of Road base and Salvaged Aggregate (Case 2)

When material in the existing road surface is to be used for mixing, the surface shall first be scarified
lightly and bladed to uniform grade and to the cross section shown on the Drawings. The reshaped
surface shall then be scarified again to such depth as is ordered by the Engineer and in such manner
as to leave a foundation stratum of undisturbed material parallel, both in profile and cross section, to
the proposed finished surface. The loosened material shall be bladed aside into a windrow at the side
of the road, and the undisturbed under-stratum rolled, or watered and rolled, as directed.
(d) Windrowing and Sampling

Care shall be exercised to prevent the aggregate, whether new or salvaged, from becoming mixed
with earth or shoulder material. Windrows of aggregate shall be shaped uniformly and trimmed so that
accurate measurements of volume may be taken by the Engineer. The uniform windrows shall be left
undisturbed until measuring and sampling are completed. At least 1 day shall be allowed for
measuring and sampling each run.
(e) Additive
If the aggregate contains more than 2 per cent but not more than 5 per cent of moisture, the
Contractor may, at his own expense, use an additive to facilitate coating of the wet aggregate in lieu of
additional manipulation for drying purposes. The additive shall be approved by the Engineer and it
shall be added to and uniformly mixed with the bitumen in the amount specified by the Engineer but
not to exceed 2 per cent by weight of the bituminous material if a commercial grade of additive is used
or 1 per cent if a concentrated grade is used.
(f) Mixing
Bituminous material shall be applied at the rate designated by the Particular Specifications or in the
Bill of Quantities, with a tolerance of 0.01 litres per square metre. The method of bituminous material
application shall be such that it will not allow liquid bituminous material to flow on the prepared
surface. Mixing shall immediately follow and shall be continued until complete, with the bituminous
material uniformly distributed throughout the mass and the aggregate particles as uniformly and
completely coated as possible.
At the end of each day’s work, or when operations are interrupted by the weather conditions, all loose
material shall be bladed into a windrow, whether the mixing is complete or not, and shall be retained in
a windrow until operations can be resumed.
Before it is spread, the windrowed mixture shall be examined by the Engineer who shall determine
whether the mixing is complete; the bituminous content is correct; and the moisture removal
satisfactory. Should the mixture show an excess, deficiency, or uneven distribution of bituminous
material, the unsatisfactory condition shall be corrected by the addition of the required aggregate or
bituminous material and by remixing. If the mixture contains more than 50 % of the original volatile
matter or if the moisture content exceeds 1.5 % of the dry weight of aggregate, the mixture shall be
bladed and aerated or otherwise manipulated until the above maximum percentages have been
reached as determined by AASHO T 110. If necessary, the material shall be harrowed or disked and
all compressed masses of material broken up. No spreading shall be done, except when authorised by
the Engineer. Spreading on a wet road base will not be permitted.

Where approved travelling plants are used, final mixing may be accomplished by such additional
passages of the travelling mixing plant as may be required for complete mixing.
When stationary mixing plants are used, at the option of the Contractor, the production of surface-
course material shall be in accordance with standard practice for the plants, and the depositing and
spreading of the material shall be as directed by the Engineer.
(g) Laying, Compacting and Finishing
(i) Spreading and blade finishing.

After the mixing has been completed, the mixed material shall be spread from the windrow to the
required width by a self-powered, pneumatic-tyred blade grader. In spreading from the windrow, care
shall be taken to prevent cutting into the underlying road base. If necessary to prevent such cutting, a
layer of the mixture 15 mm thick shall be left at the bottom of the windrow.
(ii) Rolling finished surface.

After the mixture has been spread, the surface shall be rolled. Rolling shall be longitudinal and shall
commence at the outer edges of the road, overlapping the shoulders, and progress toward the centre,
except that on superelevated curves rolling shall progress from the lower to the upper edge. Blading
shall continue during the rolling only if so ordered by the Engineer. Rolling shall continue until the
surfacing is of uniform texture and degree of compaction, and is true to grade and cross section.
Under no circumstances shall the centre of the surface course be rolled first. Initial rolling shall be
performed with a pneumatic-tyred roller and final rolling with a 3-wheel or tandem type roller.
Where the compacted thickness of road-mix material is to be more than 50 mm, the material shall be
spread from the windrow and compacted in 2 layers, with the first layer to be bladed and rolled before
the second layer is spread.
(iii) Shaping edges

While the surface is being compacted and finished, the Contractor shall trim the edges neatly to line.
(h) Improving Unsatisfactory Areas

If at any time after the Engineer has authorised spreading of the mixture, unsatisfactory areas develop
that require additional bituminous material, additional aggregate, or additional road mixing and
consequent re-laying, re-compacting, and refinishing, the work shall be done by the Contractor when
ordered in writing by the Engineer.
6705 Tolerances
(a) Thickness Requirements

The thickness of the completed surfacing shall not vary more than 1.25cm from the thickness shown
on the Drawings. The thickness shall be controlled by measurements taken immediately after laying
the material and before compacting. Sufficient measurements of thickness shall be taken before and
after compacting to establish the relationship between the thickness of the uncompacted material and
the completed work. The thickness shall then be controlled by measurements taken of the
uncompacted material immediately behind the paver.
When the measurements indicate that an area will not be within the allowable tolerance for the
completed work, the uncompacted area shall be corrected while the material is still in workable
condition.

(b) Seal Coat

If called for in the Particular Specifications, a seal coat of the type called for shall be applied to the
finished road-mix surface. In such an event, the surface shall be opened to traffic for at least 2 weeks
before the seal coat is applied.
(c) Surface Requirements

When tested by a crown template conforming to the typical cross section shown on the Drawings, or
called for in the Particular Specifications, and a 3-metre straightedge applied at right angles and
parallel, respectively, to the centreline of the surface being tested, the variation of the surface from
each testing edge between any two contacts with the surface shall at no point exceed 10 mm for the
crown template and 5 mm for the straight edge.
(d) Stockpiling
When indicated on the Drawings, road-mix aggregate shall be stockpiled in the amounts and at the
locations so indicated. Stockpiles shall be shaped as directed by the Engineer. Stockpile sites shall be
cleared, cleaned, and levelled by the Contractor.

The quantities shall be paid for at the contract price per unit of measurement, respectively, for each of
the particular pay items listed herein and shown in the Bill of Quantities, which prices and payment
shall be full compensation for furnishing and placing all materials, including all labour, equipment,
tools, and incidentals necessary to complete the work prescribed in this Division.
When the Engineer orders in writing the reworking and refinishing of unsatisfactory portions of
previously approved surface, as provided in Sub-clause 6704 (h), the areas in square meters shall be
added to what would have been paid for had no reworking and refinishing been ordered.
2
Item 67.01 Road-mix surfacing, Case 1 ........................................................square metre (m )
2
Item 67.02 Road-mix surfacing, Case 2 ........................................................square metre (m )
The quantity of road mixing to be paid for shall be the number of square meters of road-mix surfacing
placed and accepted.
3
Item 67.03 Road-mix aggregate ....................................................................... cubic metre (m )
The quantity of aggregate including filler, to be paid for shall be the number of cubic meters, measured
in the vehicles, placed and accepted.
Item 67.04 Bituminous Binder (grade indicated) ........................................................ tonne (t)

The unit contract price per tonne of bituminous material shall be full compensation for furnishing,
hauling and storage. The quantity to be paid for shall be the number of tonnes, ordered in the
accepted work.

Series 7000: Rigid Pavements
TABLE OF CONTENTS
DIVISION 7100: RIGID (CONCRETE) PAVEMENT ...................................................................................... 459
7101 Scope ........................................................................................................................................ 459
7102 Material for Concrete ................................................................................................................ 459
(a) Cement .......................................................................................................................................... 459
(b) Water ............................................................................................................................................. 459
(c) Admixtures to concrete ................................................................................................................. 459
(d) Air-entraining admixtures ............................................................................................................. 460
(e) Aggregates .................................................................................................................................... 460
(i) Fine Aggregate .......................................................................................................................................... 460
(ii) Coarse Aggregate ...................................................................................................................................... 461
(f) Materials for joints ........................................................................................................................ 461
(i) Joint Sealers .............................................................................................................................................. 461
(ii) Preformed Expansion Joint Filler ............................................................................................................. 461
(iii) Preformed Elastomeric Compression Seals .............................................................................................. 462
(iv) Preformed Self-Expanding Cork Joint Sealer ........................................................................................... 462
(g) Materials for reinforcing steel, tie-bars and dowels ...................................................................... 462
(h) Curing materials ............................................................................................................................ 462
(i) Separation membrane .................................................................................................................... 463
(j) Concrete requirements .................................................................................................................. 463
(i) Concrete Strength ..................................................................................................................................... 463
(ii) Proportions................................................................................................................................................ 463
(iii) Determining the Mix Proportions ............................................................................................................. 463
(iv) Changes in the Mix Proportions or the Materials ..................................................................................... 464
(v) Changes in Requirements ......................................................................................................................... 464
(k) Handling, measuring and batching materials for concrete ............................................................ 464
(i) Storing the Materials................................................................................................................................. 464
(ii) Transporting .............................................................................................................................................. 465
(iii) Proportioning the Components ................................................................................................................. 465
(iv) Batch mixing............................................................................................................................................. 465
(v) Transit-mixing .......................................................................................................................................... 466
7103 Preparing the Underlying Layers ............................................................................................. 466

(a) Preparation of sub-base .................................................................................................................466
(b) Conditioning of sub-base or base ..................................................................................................466
(i) Compaction ............................................................................................................................................... 466
(ii) Wetting the sub-base ................................................................................................................................. 466
(iii) Protection .................................................................................................................................................. 466
(c) Applying a bituminous prime coat or placing a separating membrane .........................................467
7104 Placing Concrete ....................................................................................................................... 467
(a) Compacting ...................................................................................................................................467
(b) Time for placing and compacting ..................................................................................................467
(c) Adverse weather conditions ..........................................................................................................467
(i) Protection against rain and hail ................................................................................................................. 467
(ii) Cold-weather paving ................................................................................................................................. 468
(iii) Hot-weather paving ................................................................................................................................... 468
(iv) Responsibility for protection ..................................................................................................................... 468
(d) Maintaining continuity during placing .......................................................................................... 468
(e) Width of placing ............................................................................................................................ 468
7105 Side-forms, Rails and Guide Wires ........................................................................................... 468
(a) Side-forms .....................................................................................................................................468
(b) Rails ..............................................................................................................................................469
(c) Electronic control systems.............................................................................................................469
(d) Inspection of side-forms, guide wires and rails .............................................................................469
7106 Placing, Compacting and Finishing with Side-forms ................................................................ 469
(a) Placing and Spreading ...................................................................................................................469
(b) Compaction ...................................................................................................................................470
(c) Final Finishing .............................................................................................................................. 470
(d) Constructing the Concrete Pavement in More than One Contiguous Strip ...................................470
7107 Placing, Compacting and Finishing with Slip-form Equipment ................................................. 471
(a) General ..........................................................................................................................................471
(b) Placing and spreading the concrete ............................................................................................... 471
(c) Compacting and finishing .............................................................................................................471
(d) Constructing the concrete pavement in more than one contiguous strip .......................................471
(e) Track support.................................................................................................................................471
7108 Placing, Compacting and Finishing with Hand Equipment ....................................................... 471
(a) General ..........................................................................................................................................471

(b) Forms ............................................................................................................................................ 472
(c) Placing, spreading, compacting and finishing the concrete .......................................................... 472
7109 Steel Reinforcement ................................................................................................................. 472
(a) General .......................................................................................................................................... 472
(b) Jointed reinforced concrete slabs .................................................................................................. 473
(c) Continuously reinforced concrete slabs ........................................................................................ 473
7110 Surface Texture......................................................................................................................... 473
(a) General .......................................................................................................................................... 473
(b) Equipment ..................................................................................................................................... 474
(i) Burlap Drag Equipment ............................................................................................................................ 474
(ii) Tine Grooving Device (Grooving Comb) ................................................................................................. 474
(iii) Burlap-Drag-and-Grooved Texture ........................................................................................................... 474
(c) Hand texturing .............................................................................................................................. 474
7111 Curing ....................................................................................................................................... 475
7112 Transverse Joints ..................................................................................................................... 475
(a) General .......................................................................................................................................... 475
(b) Contraction joints .......................................................................................................................... 476
(c) Expansion joints ............................................................................................................................ 476
(d) Warping joints ............................................................................................................................... 476
(e) Construction joints ........................................................................................................................ 476
7113 Longitudinal Joints .................................................................................................................... 477
(a) General .......................................................................................................................................... 477
(b) Longitudinal construction joints ................................................................................................... 477
7114 Joint Grooves ............................................................................................................................ 477
(a) General .......................................................................................................................................... 477
(b) Sawn transverse and longitudinal joint grooves ............................................................................ 478
(c) Wet-formed longitudinal joint grooves ......................................................................................... 478
(d) Construction joint grooves in surface slabs................................................................................... 478
(e) Groove formers and bottom crack inducers .................................................................................. 478
7115 Tie Bars and Dowels ................................................................................................................. 479
(a) General .......................................................................................................................................... 479
(b) Tie bars.......................................................................................................................................... 479
(c) Dowels .......................................................................................................................................... 480
7116 Sealing of Joint Grooves .......................................................................................................... 480
(a) General .......................................................................................................................................... 480

(b) Preparation of Joint Grooves for Sealing ...................................................................................... 480
(c) Sealing with applied sealants ........................................................................................................481
(d) Sealing with compression seals .....................................................................................................481
7117 Trial Pavement .......................................................................................................................... 482
(a) General ..........................................................................................................................................482
(b) Further trial sections and permission to start constructing the pavement ......................................482
7119 Process Control ........................................................................................................................ 482
7120 Quality Control and Workmanship ............................................................................................ 483
(a) General ..........................................................................................................................................483
(b) Compressive-strength control........................................................................................................483
(c) Relationship between the Compressive and Flexural Strengths of Concrete ................................ 483
(d) Air Content of Concrete ................................................................................................................483
(e) Unacceptable Work or Materials ...................................................................................................483
(f) Acceptance of Concrete of Inferior Strength or Thickness at Reduced Payment .......................... 483
7121 Remedial Work (Rehabilitation) ................................................................................................ 484
(a) Removing concrete ........................................................................................................................ 484
(b) Removing high spots ..................................................................................................................... 484
(c) Repairing joints ............................................................................................................................. 484
(d) Repairing cracks ............................................................................................................................ 484
(e) Rehabilitation of concrete pavements ........................................................................................... 484
(f) Removal of existing concrete ........................................................................................................485
(g) Placing new concrete ..................................................................................................................... 485
(h) Surface texture .............................................................................................................................. 485
(i) Joints, tie bars and dowels .............................................................................................................485
(j) Repairing joints and cracks in existing concrete pavement ........................................................... 486
(k) Retexturing ....................................................................................................................................486
7122 Opening to Traffic ...................................................................................................................... 486
DIVISION 7200 ULTRA-THIN REINFORCED CONCRETE PAVEMENT ........................................................... 494
7201 Scope ........................................................................................................................................ 494
7202 Material ..................................................................................................................................... 494
(a) Cement ..........................................................................................................................................494
(b) Concrete ........................................................................................................................................494

(c) Concrete Aggregate ....................................................................................................................... 494
(d) Steel Reinforcement ...................................................................................................................... 495
(e) Water ............................................................................................................................................. 495
(a) Preparation .................................................................................................................................... 496
(b) Reinforcement ............................................................................................................................... 496
(c) Concrete ........................................................................................................................................ 496
(d) Construction Joints........................................................................................................................ 497
(e) Longitudinal Joints ........................................................................................................................ 497
(f) Curing ........................................................................................................................................... 497
7205 Laboratory and Site Testing ...................................................................................................... 497
(a) General .......................................................................................................................................... 497
(b) Site Control ................................................................................................................................... 498
DIVISION 7300 NON-REINFORCED CONCRETE PAVEMENT (NRC) ........................................................... 500
7301 Scope ........................................................................................................................................ 500
7302 Materials ................................................................................................................................... 500
(a) Cement .......................................................................................................................................... 500
(b) Concrete ........................................................................................................................................ 500
(c) Concrete Aggregate ....................................................................................................................... 500
(d) Load Transfer Dowels ................................................................................................................... 500
(e) Water ............................................................................................................................................. 500
(a) Slabs .............................................................................................................................................. 501
(b) Joints ............................................................................................................................................. 501
(c) Concrete ........................................................................................................................................ 501
7305 Laboratory and Site Testing ...................................................................................................... 502
(a) General .......................................................................................................................................... 502
(b) Site Testing .................................................................................................................................... 502

LIST OF TABLES
Table 7102/1: Gradation of Fine Aggregate ......................................................................................... 460
Table 7102/2: Nominal Size of Coarse Aggregate ............................................................................... 461
Table 7102/3: Gradation for Coarse Aggregate ................................................................................... 461
Table 7202/1: Gradation of Fine Aggregate ........................................................................................ 495
Table 7205/1: Frequency of Laboratory Testing .................................................................................. 498
Table 7205/2: Site Inspection Criteria .................................................................................................. 498
Table 7302/1: Gradation for Coarse Aggregate ................................................................................... 500
Table 7305/1: Frequency of Laboratory Testing .................................................................................. 502
Table 7305/2: Site Inspection Criteria .................................................................................................. 503

Division 7100: Rigid (Concrete) Pavement
7101 Scope
This Division covers the construction of a surface course of Portland cement concrete, with or without
reinforcement, and includes, inter alia, the specifications for materials, the placing and compacting of
concrete, applying the surface texture, and constructing the joints.
7102 Material for Concrete
(a) Cement
Cement used for concrete shall be Portland cement, Type I or Type II conforming to AASHTO M 85 or
equivalent ISO standard class.
Portland cement, Type II, which has been pre-blended with a maximum of 15 per cent fly ash, by
weight, and conforming to AASHTO M 240, may be used. When blended Portland cement is used, no
additional fly ash shall be added.
Different brands of cement, or the same brand of cement from different mills, shall not be mixed.
The use of other cementitious binders may be allowed by the Engineer, provided that it can be proved
by the Contractor that they perform similarly to the cements specified above.
Suitable means shall be provided for storing and protecting the cement against dampness. Cement
which for any reason has become partially set or which contains lumps of caked cement will be
rejected. The temperature of the cement at the time of delivery to the mixer shall not exceed 71ºC.
(b) Water
Water used in mixing or curing shall be clean and free of oil, salt, acid, alkali, sugar, vegetable, or
other substances harmful to the finished product.
Water shall be tested in accordance with, and meet the requirements of, AASHTO T 26. Water known
to be of potable quality may be used without testing.
Where the source of water is relatively shallow, the intake shall be so enclosed as to exclude silt, mud,
grass, or other foreign materials.
(c) Admixtures to concrete

No admixtures shall be used without the written permission of the Engineer.
“Accelerating”, “retarding” and “water-reducing” chemical admixtures shall comply with

AASHTO M 194. When a retarding admixture is required it shall be Type D.
Care should be taken not to mix chemical admixtures unless they are compatible.
Chloride accelerators shall not be used. Admixtures shall not contain calcium chloride, calcium
formate, or triethanolamine.
An air-entraining agent shall be included in the mix.
The Contractor shall submit details of the nominated mix and shall nominate the proprietary source,
type and name for each admixture to be used. Documentary evidence of the quality and chemicals
compatibility shall be furnished by the Contractor to the Engineer upon request at any stage of the
work.

(d) Air-entraining admixtures

Air -entraining admixtures shall comply with AASHTO M154.
A certified affidavit and test result evidence based on tests made in a recognised laboratory shall be
submitted to the Engineer by the Contractor.
(e) Aggregates
Aggregates from a single source shall be used in the Works unless specifically authorised by the
Engineer. The maximum soluble sulphate salt content of aggregates, expressed as percentage SO3 by
mass, shall not exceed 0.1%.
Aggregates containing more than the maximum permissible amount of sulphates, or with visible
encrustation of salts, shall be washed and drained before being used in concrete. The Engineer may
direct washing or re-washing of the aggregates until the Engineer is satisfied that harmful quantities of
salts are not present.
(i) Fine Aggregate

Fine aggregate can be natural sand, manufactured sand, or a combination of natural and
manufactured sand, meeting the following requirement:
 Natural sand:- shall be composed of clean, hard, durable, uncoated grains, free from lumps or
flaky particles, organic matter, loam, or other deleterious substances.
 Manufactured sand:- shall be made from stone meeting all the quality requirements for coarse
aggregates.
 Mixtures of natural sand and manufactured sand:- When the blend is approved the two
materials shall be stored and batched separately.
 Organic impurities:- All fine aggregate shall be free from harmful amounts of organic
impurities. Fine aggregates subjected to the colourmetric test of AASHTO T 21 for organic
impurities and producing a colour darker than 3 shall not be used unless the relative strength
at 7 and 28 days is not less than 95% when tested in accordance with AASHTO T 71.
 Soundness:- When the fine aggregate is subjected to five alternations of the sodium sulphate
soundness test AASHTO T 104 the weighted loss shall not exceed 10% by weight.
 Gradation of fine aggregate:- For all classes of Portland cement concrete and concrete
pavement shall confirm to the gradation in Table 7102/1.
Table 7102/1: Gradation of Fine Aggregate
AASHTO Standard Sieve

Percentage by weight passing
Designation (mm)
9.5 100
4.75 95 - 100
2.36 80 - 100
1.18 50 - 85
0.600 25 - 60
0.300 10 - 30
0.150 1 - 10
0.075 0-3
(x)

(ii) Coarse Aggregate

Coarse aggregate for Portland cement concrete shall conform to the following requirements:
 General:- Coarse aggregate shall be clean, tough, durable gravel, crushed gravel, hard
durable rock, metallurgical furnace slag or gravel. It shall be free from soft, thin, elongated or
laminated pieces. If required, coarse aggregate shall be washed to produce a clean
aggregate.
 The Los Angeles abrasion value obtained from the AASHTO T96 test shall not exceed 40%.
 The weighted loss shall not exceed 15% in the Sodium Sulphate Soundness test (AASHTO T-
104).
 Adherent coating in accordance with Federal Lands Highway of the FHWA requirement
FLH T 512:- shall not exceed 1.0%.
 The nominal size of coarse aggregate shall not exceed the values shown in Table 7102/2.
 Gradations of coarse aggregate: Shall be as shown in Table 7102/3.
Table 7102/2: Nominal Size of Coarse Aggregate

Maximum Nominal Size of
Slab Thickness (mm)
Coarse Aggregate (mm)
≥ 175 37.5
≥ 150 and ≤ 175 25
≥ 100 and ≤ 150 19
Table 7102/3: Gradation for Coarse Aggregate
AASHTO Standard Percentage by Mass Passing

Sieve(mm) 50 37.5 25 19 12.5 9.5 4.75 2.36 1.18
37.5 to 19.0 100 90-100 20-55 0-15 0-5
37.5 to 4.75 100 95-100 35-70 10-30 0-5
25.0 to 12.5 100 90-100 20-55 0-10 0-5
25.0 to 9.5 100 90-100 40-75 15-35 0-15 0-5
25.0 to 4.75 100 95-100 25-60 0-10 0-5
19.0 to 9.5 100 90-100 20-55 0-15 0-5
19.0 to 4.75 100 90-100 20-55 0-10 0-5
19.0 to 2.36 100 90-100 30-65 5-25 0-10 0-5
12.5 to 4.75 100 90-100 40-70 0.15 0-5
12.5 to 2.36 100 90-100 40-70 5-25 0-10 0-5
(f) Materials for joints
(i) Joint Sealers

Hot-poured joint sealer shall conform to AASHTO M 301. Cold-poured joint sealant shall be silicone
type conforming to US Federal Specification TT-S-1543A, Class A. The sealant shall be a one-part,
low-modulus silicone rubber type with an ultimate elongation of 1200 per cent.
When specified, Silicone Sealant shall meet the detailed requirements as stated in the Particular
Specifications or as provided by the manufacturer. The test methods shall conform to ASTM-D-792,
ASTM D-2240, ASTM C-794 & ASTM C793-7. The silicone joint sealant shall be grey in colour and
shall be stored and installed in accordance with the manufacturer’s written instructions.
(ii) Preformed Expansion Joint Filler

Preformed fillers for joints shall conform to AASHTO M 33, AASHTO M 153 Type II, and
AASHTO M 213 and shall be punched to admit the dowels. The filler for each joint shall be furnished
in a single piece for the full depth and width required for the joint. When the use of more than one
piece is authorised for a joint, the abutting ends shall be fastened securely, and held accurately to
shape by stapling or other positive fastening.

The use of preformed, closed-cell, polyethylene foam backer joint filler shall conform to ASTM D 3204,
Type I and shall be limited to vertical applications only.
(iii) Preformed Elastomeric Compression Seals

Preformed elastomeric compression seals used shall comply with the requirements of
AASHTO M 220. The seals shall be manufactured in accordance with an extrusion process, from an
elastomeric material consisting entirely of polychloroprene, which is subsequently vulcanized.
(iv) Preformed Self-Expanding Cork Joint Sealer

This shall comply with the requirements of AASHTO M 153.
(g) Materials for reinforcing steel, tie-bars and dowels

Reinforcing steel for concrete pavements shall be of the type, length, size, spacing, and quantity
shown on the plans and shall meet the following requirements:
 All steel shall be clean and free from mill scale, loose rust or oil.
 Reinforcement steel may be either deformed steel bars or cold-drawn steel wire conforming
to the following:
o Bar Mats that shall be cold-drawn steel wire or deformed steel bars from new billet
steel conforming to AASHTO M 31 M. The bars shall be size No. 10. All bars shall
have the tensile requirement of Grade 300 or 400. Fabrication of bar mats using
deformed steel bars shall be in accordance with ASTM A 184/A 184 M. Bar mats
fabricated using rolled cold-drawn steel wire shall be in accordance with ASTM A 82.
o Welded Steel Wire Fabric conforming to AASHTO M 55M/M 55. Wire fabric shall not
be less than 1.5 metres in width and shall be shipped in sheets and not in rolls.
 Tie bars shall be deformed bars conforming to AASHTO M 31 M. All bars shall have the
tensile requirements of Grade 400. Tie bars for use across joints shall have an epoxy coating
conforming to AASHTO M 284/M 284 M except that the thickness of the cured coating shall be
250 ± 50 microns.
 Dowel bars shall be plain, round bars conforming to AASHTO M 254 type A or B. They shall
be free from burring or other deformation restricting slippage in concrete. Dowel bars shall be
coated with an approved material to break the bond between the steel and concrete.
(h) Curing materials

Curing materials for Portland cement concrete shall conform to the following:
 Liquid membrane-forming compounds shall conform to AASHTO M 148, Type 1-D, clear or
translucent with fugitive dye, or Type 2, white pigmented.
 Burlap cloth made from jute or kenaf shall conform to AASHTO M 182, Class 4.
 White polyethylene sheeting shall conform to AASHTO M 171 for white opaque polyethylene
film.
 White burlap-polyethylene sheeting shall conform to AASHTO M 171.
 Waterproof paper shall conform to AASHTO M 171.
 Hay or straw when used for insulation in cold weather shall be dry and shall not be reused
unless otherwise approved.
 Liquid membrane -Forming compounds, shall conform to AASHTO M 148

(i) Separation membrane

Separation membranes, to be used between jointed reinforced concrete surface slabs or unreinforced
concrete surface slabs and the sub-base, shall be impermeable plastic sheeting 125 microns thick.
(j) Concrete requirements

Concrete shall be composed of Portland cement, fine aggregate, coarse aggregate, fly ash, water-
granulated blast- furnace slag, water, and chemical admixtures as proposed by the Contractor and
approved by the Engineer to produce concrete of the specified strength and workability.
Mix design, manufacture, placing, compaction and finishing of concrete shall be the responsibility of
the Contractor.
(i) Concrete Strength

The design method described in the prevailing version of ERA’s Pavement Design Manual, Volume 2
Rigid Pavements, provides designs for a range of concrete strengths from a minimum compressive
strength after 28 days of 30 MPa up to a maximum of 50 MPa.
(ii) Proportions
The concrete shall contain the amount of cement as directed by the Engineer but in no case shall the
3
concrete contain less than 320 kg/m .
The water:cement ratio, including moisture on the aggregates, shall be not more than 0.53. This shall
be maintained by use of chemical admixtures and or additional water if necessary.
The concrete shall be uniformly plastic and workable. The consistency of the concrete shall be
determined by the slump test in accordance with Method SC-T-42. The slump shall be in the range of
25 mm to 60 mm; or 37.5 mm, ± 25 mm for slip-form paving; and 100 mm maximum slump for hand or
other means of paving.
Where the Contractor wishes to use an air-entraining agent, the total air content in the freshly mixed
concrete shall be M ± 1%, where M is the target value within the limits of 2% to 4%. Tests shall be
conducted in accordance with ASTM C 231.
The percentage of entrained air voids in the mix shall be from 3 to 6 per cent.
Where concrete is to be cast between fixed forms the nominal maximum aggregate size of the mix
shall be 40 mm.
Where the Engineer has approved of the placement of concrete by means of a self-propelled slip-form
paving machine, the mix design, slump and workability shall suit the machine proposed for use.
(iii) Determining the Mix Proportions

The preliminary proportions of cement and aggregate required for producing concrete which complies
with the requirements of these Specifications shall be determined by way of laboratory tests on
concrete manufactured from the cement, coarse and fine aggregates, admixtures (if any) and water
proposed for use in the Works.
At least sixty (60) days prior to the construction of the trial pavement as specified in Clause 7117, the
Contractor shall submit to the Engineer samples of all the components of the concrete proposed for
use, plus a report by an approved testing laboratory showing the mix proportions proposed for each
combination of material sources for the concrete. The report shall also show the following:
 The results of tests on the specified properties of all components.

 The relationship between the 28-day compressive strength and flexural strength of the
concrete at each of at least three water cement ratios namely 0.48, 0.53 and 0.58.
 The effect of the particular admixture (if any) proposed by the Contractor in regard to
variations in admixtures, air content (if air entraining) and concrete setting and sawing times.
 The effect of at least three water contents on concrete consistency.

 In determining the relationship between compressive and flexural strength, the tests shall be
based on not less than six compressive-strength specimens and six flexural-strength
specimens for each water:cement ratio. All strength tests shall be conducted in accordance
with ASTM C 39 and ASTM C 78.
(iv) Changes in the Mix Proportions or the Materials

If during the progress of the work the requirements set out in sub-clause 7102(j) are not met by
concrete manufactured from the materials or material mix proportions being used, the Contractor shall
immediately cease producing such concrete and shall effect such changes to the mix proportions
and/or materials as may be necessary in order to meet the requirements.
If during the progress of the work the Contractor wishes to use materials or mix proportions other than
those originally approved, or if the materials from the sources originally approved change in regard to
properties, the Contractor shall, before proceeding with further work, submit adequate evidence to the
Engineer that the new materials or combination of materials will produce concrete which complies with
the requirements of sub-clause 7102(j) and will not bring about detrimental changes in the properties
of the concrete.
Any such changes made shall be at the Contractor's expense, and no extra payment will be allowed
by reason of such changes.
Where concrete is placed by hand and vibrated or finished with hand equipment, the requirements of
sub-clause 7102(j) shall remain applicable irrespective of the size of the concrete panel or concrete
patch placed. The mix proportions, however, shall be adjusted to promote hand placing, vibrating and
finishing. Only if the Contractor has produced written proof to the Engineer that the requirements of
sub-clause 7102(j) cannot be complied with under the specific circumstances, will the Engineer
change the requirements in accordance with sub-clause 7102(j) at his own discretion.
(v) Changes in Requirements

The Engineer shall have the power, at any time during the progress of the work, to order changes in
the requirements set out in sub-clause 7102(j). In such cases, the Contractor shall be compensated in
accordance with the terms of the General Conditions for the additional cost of materials or additional
handling, placing and/or other costs, if any, entailed by such changes. If such changes result in
savings, the Engineer shall recover such savings from the Contractor.
(k) Handling, measuring and batching materials for concrete
(i) Storing the Materials

Stockpiling of aggregates; the location and preparation of the sites; the minimum size of pile and the
method adopted to prevent coning or other segregation of component sizes; shall be subject to the
Stockpiles shall be built up in layers of not more than one (1) metre in thickness. Each layer shall be
completely in place before beginning the next, which shall not be allowed to cone down over the next
lower layer. Under no circumstances will coning of stockpiles be permitted.
Aggregates from different sources shall not be stockpiled together unless approved by the Engineer.
The fine aggregate and coarse aggregate shall be separately weighed into the hopper in the
respective amounts set by the Engineer in the job mix approval.
Cement shall be stored in a silo or in a dry weatherproof shed with a raised wooden floor, and each
consignment shall be stacked separately. Cement shall be used in the order in which it has been
delivered at the site.
The various types of admixtures shall be properly marked and stored separately.
(ii) Transporting
When mixing of the concrete is to be done at the job site, materials shall be transported from the
batching plant to the mixer in vehicles appropriate for the job.
In the dry batch process, bulk cement shall be transported to the roadside paver in watertight
compartments carrying the full amount of cement required for the batch; or, if permitted, between the
fine and coarse aggregate.
Concrete shall be so transported to its final position that segregation or loss of any of the ingredients,
or contamination will be prevented and that the mix is of the required workability at the point and time
of placing.
Concrete shall be protected against rain, heat, direct sunlight and/or evaporation by means of covers
on all open vehicles. No additional water may be added in transit or where delivered.
The time lapse from the moment when the cement and aggregate are intermingled up to the time of
placing and compacting the concrete shall not exceed sixty (60) minutes when concrete is transported
in truck agitators, and shall not exceed forty-five (45) minutes in mild weather or thirty (30) minutes
when the concrete temperature is 30ºC or higher when transported in ordinary trucks.
(iii) Proportioning the Components

All components shall be accurately proportioned in approved automatic proportioning devices to within
the following tolerances, and supplied separately at the mixing drums.
 Cement: ± 2% of the prescribed mass of cement.

 Aggregate: Each fraction within ± 3% of the prescribed mass of the fraction in question.
 Water: ± 2% of the prescribed volume or mass.
 Admixtures: Admixtures shall be admixed in part of the mixing water after having been
carefully measured in an automatic proportioning device capable of proportioning the
admixture in quantities which will not deviate by more than 2% from the required quantities,
and shall be done so as to spread the agent uniformly throughout the entire concrete mix
during the mixing process.
Water for the mix may be measured by volume or by weight. The accuracy of the water-measuring
equipment shall be within a range of error of less than 1%, and shall be so arranged that the
measurement will not be affected by variations of pressure in the water supply line and will be
accurate under all construction conditions encountered.
Methods and equipment for adding air-entraining agent or other admixtures into the batch, shall be as
recommended by the manufacturer.
(iv) Batch mixing

All concrete shall be mixed in mechanically operated batch mixers. The concrete may be mixed at the
site of the work in a central-mix plant; in truck mixers when allowed, or in a roadside paver.
The mixing period shall be at least 90 seconds, but may be reduced to as little as 50 seconds, or
increased by the Engineer if necessary, to produce a homogeneous mass.
The production capacity of the mixing plant shall be in accordance with the capacity of the paver used.
Where the mixing plant is supplied with more than one drum, the same unit shall be used for
proportioning the components.
The drums shall always be kept clean, and all build-up shall be removed. The total period between the
times that the cement is placed in the drums until mixing starts shall not exceed 15 minutes.

An overload up to 10% above the mixers nominal capacity may be permitted provided concrete test
data for strength, segregation, and uniform consistency is satisfactory and no spillage of concrete
occurs.
Concrete shall not be mixed when either the coarse or fine aggregate contains frozen particles.
No more concrete shall be mixed than can be placed, finished, and covered during daylight, unless the
Engineer approves an artificial lighting system.
(v) Transit-mixing
The Contractor will be permitted to use appropriate truck mixers, which agitate previously mixed
concrete in transit.
Mixed concrete from the central mixing plant shall be transported in truck mixers, truck agitators, or
non-agitating trucks. The time elapsing from the time water is added to the mix until the concrete is
deposited in place shall not exceed thirty (30) minutes when the concrete is hauled in non-agitating
trucks; or sixty (60) minutes when hauled in truck mixers or truck agitators.
7103 Preparing the Underlying Layers
(a) Preparation of sub-base

The underlying layers shall be constructed in accordance with the Standard Specifications and the
Particular Specifications up to the level of the underside of the concrete slab.
The Contractor shall note the provisions regarding the construction tolerances for underlying
pavement layers and shall make provision in his prices for any additional concrete, which may be
necessary in respect of irregularities in the layer underlying the concrete pavement.
The sub-base shall be brought to reasonably close conformity to the lines, grades and typical sections
as shown on the plans or as designated by the Engineer.
The sub-base shall include an area 900 mm in width extending beyond the edges of the road base or
pavement unless shown otherwise on the Drawings.
When kerb and gutter is constructed contiguous with the pavement, the sub-base shall include an
area 610 mm in width extending beyond the back of the curb and gutter.
The sub-base shall be completed for at least 800 metres in advance of concrete placing operations
when this distance is available.
(b) Conditioning of sub-base or base
(i) Compaction
The entire sub-base or base layer shall be thoroughly compacted. Any portion of the sub-base that is
not accessible to a roller shall be compacted with hand tampers to obtain the density requirements for
the material.
(ii) Wetting the sub-base

The sub-base shall be kept continuously wet for a period of at least one (1) hour before the concrete is
placed. Immediately before the concrete is placed, the excess water shall be broomed off the road
ahead of the paver so as to ensure that the sub-base will still be damp when the concrete is placed,
but no puddles of water or deleterious matter shall be left on the road.
(iii) Protection
Before placing any surfacing material on any section, open drains and drains along that section shall
be completed to drain the subgrade effectively. Until the sub-base or base has been checked and
approved, no material shall be deposited thereon.
(c) Applying a bituminous prime coat or placing a separating membrane

Unless otherwise specified in the Specifications, a bituminous prime coat shall be applied to the
completed and approved sub-base or capping layer as specified in Division 6100 at a rate of
application ordered by the Engineer; or, where shown on the Drawings, a separating membrane shall
be placed.
Before any pavement concrete is placed, the bituminous prime coat shall be checked and any areas
having deficient or poor coverage, or where the bituminous coating has been damaged, shall be
repaired as directed by the Engineer. The sprayed surface shall then be thoroughly cleaned. The
bituminous prime coat shall be dry before any reinforcing steel, tie bars, dowels or concrete may be
placed.
Separation membranes, to be used between jointed reinforced concrete surface slabs or unreinforced
concrete surface slabs and the sub-base, shall be laid flat without creases. Where an overlap of plastic
sheets is necessary, this shall be at least 300 mm.
7104 Placing Concrete
(a) Compacting
The concrete shall be fully compacted by means of approved equipment and shall be free from
honeycombing and planes of weakness. The average amount of air voids as measured in concrete
cores shall not exceed 3% without air-entrainment when measured by ASTM C 173.
Over-vibration resulting in segregation, surface laitance, or leakage (or any combination of these) will
not be acceptable.
No paving in the downhill direction will be allowed if tearing of the concrete occurs. The Contractor
shall take the necessary measures to the satisfaction of the Engineer to prevent tearing of the
concrete for example by carrying out the paving in the uphill direction.
(b) Time for placing and compacting

The placing, compacting and finishing of the concrete shall be carried out as quickly as possible, and
the operations shall be so arranged that in any transverse section of the pavement the concrete shall
be fully compacted and finished within 2½ hours of having been mixed. This time shall be reduced by
30 minutes for every 5ºC by which the concrete temperature is above 20ºC at the time of placing,
unless otherwise permitted by the Engineer.
Unless adequate lighting facilities, approved by the Engineer, are provided beforehand by the
Contractor, the placing of concrete pavement shall cease in good time so that the finishing operation
can still be completed during daylight hours.
(c) Adverse weather conditions
(i) Protection against rain and hail

No concrete shall be placed during rainy weather. For the concrete to be properly protected against
rain and hail before it has sufficiently hardened, the Contractor shall have available at all times frame-
mounted waterproof covers for protecting the surface of the unhardened concrete. In addition, when
slip forms are used, the Contractor shall also provide acceptable emergency protection for the slab
edges.
When rain is imminent, all paving operations shall cease and the Contractor shall take the necessary
steps to protect the unhardened concrete. The Contractor shall be responsible for the repair of any
damage to the concrete, the texturing or the curing compound that may occur.

(ii) Cold-weather paving

All reasonable precautions shall be taken to prevent the temperature of the pavement concrete from
failing below 5ºC during the first 48 hours after casting.
When prevailing temperatures are low or when cold weather is forecast and there is a danger that the
temperature of the freshly constructed concrete pavement will fall below the prescribed limits, the
Contractor shall either cease all pavement operations; or he may be permitted to proceed, provided
that the Engineer is satisfied that adequate protective measures are available and will be taken to
ensure that the temperature of the pavement will be maintained above 5ºC for the period stated.
The Contractor will be responsible for the quality and strength of the concrete placed during cold
weather, and any defective concrete shall be removed and replaced without additional compensation.
Concrete shall not be mixed when either the coarse or fine aggregate contains frozen particles.
(iii) Hot-weather paving

When paving is done during hot weather and when the temperature of the fresh concrete can be
expected to exceed 25ºC, the Contractor shall implement appropriate precautionary measures to
place the concrete at the coolest temperature practicable.
Paving operations shall cease when the concrete temperature as discharged at the paver exceeds
32ºC.
(iv) Responsibility for protection

The Contractor shall be responsible for the quality and strength of the concrete placed and for its
protection. Any concrete damaged by adverse weather (e.g. any combination of high ambient
temperature, low humidity, wind, rain and hail) shall be removed and replaced at the Contractor’s
expense.
(d) Maintaining continuity during placing

The Contractor shall make adequate advanced arrangements for preventing delay in delivering and
placing the concrete.
An interval of more than thirty (30) minutes between the placing of any two consecutive batches or
loads of concrete shall constitute sufficient reason for the Engineer to have the paving operations
stopped. The Contractor shall then, at his own expense, make a construction joint in the concrete
already placed, at the location and of the type directed by the Engineer.
Paving operations shall be continuous, and the rate of paving shall be adjusted to suit the rate of
delivery of the concrete.
(e) Width of placing

The width of concrete pavement strip to be placed in a single uninterrupted operation shall be as
shown on the Drawings or specified in the Particular Specifications.
7105 Side-forms, Rails and Guide Wires
(a) Side-forms
Side-forms and rails shall be so designed, manufactured, set and supported that the completed
concrete pavement will comply with all the requirements of Clause 7118.
Where the forms are tested with a 3m straightedge, the top edge shall not deviate by more than 3mm
at any place; or the sides by more than 6mm. The sides shall not deviate by more than 3mm from the
vertical. The height of the side-forms shall not be less than the nominal thickness of the concrete slab,

less 15 mm; and the resulting opening between the side-forms and the layer on which it is supported
shall be caulked with a stiff mortar consisting of one (1) part of rapid-hardening cement and three (3)
parts of sand by volume and finished vertically on the inside. The mortar shall have hardened before
any concrete may be cast against it.
The rails, side-forms and running surface shall be kept clean in front of the wheels of all paving
equipment.
Side-forms shall not be removed before the concrete has hardened sufficiently to prevent damage
being done to the sides and loosening of tie-bars or dowels, if any; and not earlier than six (6) hours
after the completion of the construction of the slab. The side-forms shall also be removed in a timely
manner to permit the sawing of transverse joints up to the edges of the concrete slab.
Projecting tie-bars and/or the concrete shall not be damaged during removal of the side-forms.
Before any side-forms may be ordered or brought onto the site, particulars regarding the side-forms
shall have been approved by the Engineer.
(b) Rails
The wheels of spreading and finishing machines and frame-mounted covers shall not run directly on
the top surface on the side-forms but on rails rigidly attached to the forms, unless the forms are
specially made to double as rails.
(c) Electronic control systems

Where a slip-form paver is used, the alignment levels for placing the concrete shall be controlled
automatically from guide wires by sensors attached at the four corners of the slip-form paving
machine. The alignment and level of ancillary machines for finishing, texturing and curing shall be
automatically controlled relative to the guide wires and to the surface and edges of the slab.
Guide wires shall be so designed, manufactured and fixed that the paver will be capable of producing
a completed slab, which will comply with the requirements of Clause 7118.
Other control methods will also be considered, and should the Engineer be satisfied that they will
produce satisfactory results, their use will have to be approved in writing.
(d) Inspection of side-forms, guide wires and rails

Before any concrete may be cast, the Engineer shall approve all assembled side-forms, guide wires
and rails. For this purpose, the Engineer shall be given sufficient notice and opportunity.
Approval by the Engineer will not relieve the Contractor of any of his obligations to construct the
concrete slab in accordance with the specified dimensions and tolerances.
7106 Placing, Compacting and Finishing with Side-forms

The paving train shall consist of several powered machines that spread, compact, finish, texture and
cure the concrete in a continuous operation.
(a) Placing and Spreading

The concrete shall be spread uniformly by means of a purpose-made mechanical hopper spreader
running on rails and capable of spreading the concrete uniformly to a specified level and to a uniform
uncompacted density over the entire surface of the slab. The machines shall be capable of being
rapidly adjusted for changes in slab thickness or crossfall.

(b) Compaction
The concrete shall be fully compacted by vibration or by a combination of mechanical surface
vibration, internal vibration and tamping. The power supply to the vibrators shall cut out automatically
as soon as the compaction equipment stops moving.
Suitable internal vibrators shall be used against the side-forms and at joint assemblies to ensure
compaction throughout the pavement layer.
(c) Final Finishing

The surface of the concrete shall be finished smooth and true to grade and level by means of an initial
finishing machine equipped with a transverse or oblique oscillating beam.
The final finish of the surface of the slab shall be carried out by a machine that incorporates twin
oblique oscillating finishing beams. The beams in the case of both machines shall be readily
adjustable for both height and tilt. The leading beam shall be vibrated. The beam shall be supported
on a carriage with two wheels on either side, at least four (4) metres apart in the longitudinal direction.
The oscillating beams shall be of rectangular section, spanning the full width of the slab and each
weighing not less than 170 kg/m.
Hand-finishing of the concrete surface shall be reduced to the absolute minimum and shall be used
only to correct minor imperfections and marks on the surface.
Before the concrete starts setting, all pavement edges and the edges of joints shall be rounded off to
the prescribed radius.
After finishing, the Contractor shall test the concrete surface with a straightedge of at least 3m in
length. Irregularities indicated by the straightedge shall be removed with a long-handled hand-
operated scraping straightedge of at least 3m length. A gangplank shall be used when walking on the
concrete.
(d) Constructing the Concrete Pavement in More than One Contiguous Strip
Where concrete is placed adjacent to an existing pavement, that part of the paving equipment running
on the existing pavement shall have flanged wheels on flat-bottom section rails weighing not less than
15 kg/m or by replacing the flanged wheels on that side of the machines by smooth flangeless wheels.
Before the paving operation commences, the surface regularity of the existing pavement shall comply
with Division 10100 of these specifications and be thoroughly cleaned and brushed to remove all
extraneous materials. The wheels shall run at a distance of not less than 300 mm from the edge of the
pavement to prevent the pavement edge from spalling or cracking.
No equipment shall be run on the existing pavement until the concrete is strong enough to prevent
damage from occurring, but in any case not earlier than fourteen (14) days after the construction of the
slab.
Where visible cracks occur or any other damage is done to the pavement, further work involving the
paver shall be suspended immediately.
The Contractor shall repair all damage at his own cost.

7107 Placing, Compacting and Finishing with Slip-form Equipment
(a) General
Slip-form paving equipment shall be used for spreading, compacting, floating and finishing the
concrete in a continuous operation and in such a manner that a minimum of finishing by hand will be
required and a dense and homogeneous concrete to the proper level and grade will be produced.
(b) Placing and spreading the concrete

The concrete shall be deposited without segregation ahead of the paver across its whole width and to
a height, which at all times is in excess of the required surcharge.
The deposited concrete shall be struck off to the necessary average and differential surcharge by
means of a strike-off plate or screw auger device extending across the entire width of the slab. The
strike-off equipment shall be capable of being rapidly adjusted for changes in slab thickness or
crossfall.
(c) Compacting and finishing

The slip-form paver shall compact the concrete over the full paved width by means of internal vibration
only or by a combination of internal and surface vibration. The vibration shall be variable with a
maximum energy output of at least 2.5 kN per metre width of slab per 300 mm depth for a laying
speed of up to 1.5 metres per minute or pro-rata for higher speeds.
The level and grades of the surface shall be automatically controlled within the prescribed tolerances
by means of a sensing device running on guide wires as specified.
The consistence of the concrete shall be so controlled that the edge slump will not exceed the
tolerance specified in Division 10100 of these specifications.
If approved by the Engineer, metal side-forms of sufficient thickness may be used to maintain the
proper shape and line.
After the concrete has been finished by the finishing devices incorporated in the slip-form paving
equipment, the surface of the concrete shall be checked by means of a straight-edge of not less than
3.0 metres in length. High spots indicated by the straightedge shall be removed by hand floats.
After the final finishing and texturing of the concrete, but before curing, the pavement edges shall be
rounded to the prescribed radius.
(d) Constructing the concrete pavement in more than one contiguous strip
Except for the wheels, which are in the case of slip-form pavers to be replaced with rubber cushioned
crawler tracks; the provisions of Clause 7106 shall apply when concrete is being placed in more than
one contiguous strip.
(e) Track support

The Contractor shall at his own cost ensure that adequate track support is provided to suit the needs
of the slip-form paver, either by extending the upper pavement layers or by providing alternative
support layers.
7108 Placing, Compacting and Finishing with Hand Equipment
(a) General
Where the slabs are too small or irregular, or the site is so restricted as to render the use of the
methods described in Clauses 7106 and 7107 impracticable, concrete shall be placed, compacted and

finished by means of hand-guided twin vibratory beams and poker vibrators. If necessary, the
consistency of the concrete shall be adjusted so as to be suitable for placing with hand-operated
equipment.
(b) Forms
Side-forms complying with the requirements of Clause 7105 shall be used.
(c) Placing, spreading, compacting and finishing the concrete

The concrete shall be placed and spread uniformly to a surcharge of about one-fifth more than the
final pavement thickness and shall then be compacted, struck off and finished to the level of the side-
forms.
The concrete shall be compacted by means of vibrating finishing beams. In addition, internal poker
vibrators shall be used for slabs thicker than 150 mm. Where used, the pokers shall be inserted at
points not more than 500 mm apart over the whole area of the slab, and adjacent to side-forms or the
edge of a previously constructed slab.
The surface shall be regulated and finished to the level of the side-forms or adjacent slabs by using
twin vibrating beams. The beams shall be of metal with a contact surface at least 50 mm wide and a
vibrating unit having a minimum centrifugal force of 4 kN with a frequency recommended by the
manufacturer or an equivalent compactive effort. The vibrating beams shall be moved forward at a
steady speed of 0.5 m to 1.0 m per minute while vibrating over the compacted surface, to produce a
smooth finish.
The surface shall then be further smoothed by at least two passes of a scraping straightedge with a
blade length of not less than 2.4 m.
The final surface finish of the concrete shall be effected by means of hand-operated floats. The
finishing of the concrete surface shall be as specified in Division 8200 of these specifications.
7109 Steel Reinforcement
(a) General
Spacing of bars shall be as indicated on the Drawings or specified in the Particular Specifications.
Laps in longitudinal bars shall not be less than 35 bar diameters or 450 mm whichever is greater. In
continuously reinforced concrete slabs, only one third of the laps may be in any one transverse
section, except in single bay width construction where half the laps may be in any one transverse
section. There shall be a minimum of 1.2 m longitudinally between groups of transverse laps or laps in
prefabricated reinforcement sheets. Alternatively, the reinforcement may be butt welded.
Laps in any transverse reinforcement shall be a minimum of 300 mm.
Where prefabricated reinforcement sheets are used and longitudinal and transverse laps would
coincide, no lap is required in the transverse bars within the lap of the longitudinal reinforcement.
These transverse bars may be cropped or fabricated shorter so that the requirements for cover are
met. Alternatively, prefabricated sheets incorporating splices (i.e. flying ends) may be used to provide
nesting of reinforcement in both directions at lap positions. The lengths of the laps shall be the
minimum values previously stated.
If the reinforcement is positioned prior to concreting, it shall be fixed on metal supports and retained in
position at the required depth below the finished surface and distance from the edge of the slab so as
to ensure that the required cover is achieved.

Reinforcement assembled on site shall be tied, or firmly fixed, at sufficient intersections to provide
sufficient rigidity to ensure that the reinforcement remains in the correct position during construction of
the slab.
Alternatively, when a reinforced concrete slab is constructed in two layers, the reinforcement in the
form of prefabricated sheets may be placed on or into the bottom layer, which shall be spread and
compacted to such a level that it will support the reinforcement without distortion at the required
position in the slab. The sheets shall be tied together at overlaps and after the second layer has been
spread and compacted, the reinforcement shall have the required cover.
When a reinforced concrete slab is constructed at maximum width of 6 m or more, the transverse
reinforcement in the centre of the slab shall be a minimum of 12 mm nominal diameter bars at 600 mm
centre to centre. This reinforcement shall be at least 600 mm longer than one third of the width of the
slab and be lapped to other transverse reinforcement bars or sheets, or be continuous across the
whole width of each slab.
(b) Jointed reinforced concrete slabs

The reinforcement shall be so placed that after compaction of the concrete, the cover below the
finished surface of the slab is as indicated on the Drawings, with a tolerance of ± 10 mm for slabs less
than 270 mm thick and ± 20 mm for slabs 270 mm thick or more.
The vertical cover between any longitudinal joint groove forming strip and any reinforcement shall be a
minimum of 30 mm.
Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any transverse
reinforcement shall terminate at the specified distance from the edge of the slab and longitudinal joints
as shown on the Drawings, with a tolerance of ± 25 mm. No longitudinal bar shall lie within 100 mm of
a longitudinal joint. The reinforcement shall terminate 300 mm ± 50 mm from any transverse joint,
excluding emergency construction joints.
(c) Continuously reinforced concrete slabs

The reinforcement shall be positioned with the diameters and spacings shown on the Drawings.
Except where otherwise shown on the Drawings, the longitudinal bars shall be parallel to the
centreline of the road.
The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at mid-
depth of the specified thickness of the slab ± 25 mm. No longitudinal bar shall lie within 100 mm of a
longitudinal joint. In reinforcement assembled on site, longitudinal bars shall be placed immediately
above any transverse bars, which shall be at right angles to the longitudinal axis of the carriageway or
as otherwise specified or shown on the Drawings.
Any transverse reinforcement shall terminate at the specified distance from the edge of the slab and
longitudinal joints as shown on the Drawings, with a tolerance of ± 25 mm.
7110 Surface Texture
(a) General
After the concrete has been placed, spread, compacted, finished and completed and before the curing
membrane is applied, the surface of the concrete shall be provided with a surface texture.
The direction of texturing shall be at right angles to the longitudinal axis of the pavement.
The surface texture shall be applied and completed before the concrete is so hard that the surface will
be torn and coarse aggregate unduly loosened during texturing.

(b) Equipment
The required texturing shall be effected by means of a machine which spans the full width of the
concrete pavement and which is guided in regard to both level and direction by the rails in the case of
side-form construction or by the paver guide wires in the case of slip-form construction.
(i) Burlap Drag Equipment

Unless otherwise authorised by the Engineer, the burlap drag shall be attached to the front of the
texturing machine or to an additional machine which spans the full width of the concrete pavement and
is placed in such a way that the full width of the concrete pavement is covered in one operation and,
when not in use, the entire drag can be lifted clear off the pavement.
The dimensions of the burlap drag shall be such that at least 1.0 m of the material is in contact with
the surface of the concrete pavement measured in the direction in which the drag is being moved. The
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burlap drag shall consist of at least two layers of 340 g/m burlap with the bottom layer at least
150 mm longer than the top layer at the dragging end; however, at the discretion of the Engineer, the
number of layers may be increased to four. The transverse threads of the trailing 150 mm to 300 mm
of the burlap drag shall be removed.
(ii) Tine Grooving Device (Grooving Comb)

The pavement shall be grooved by means of a metal tine grooving device. The tines shall be made
from flat spring steel 0.6 mm in thickness and 3 mm in width, 125 mm in length and spaced at between
12 mm and 25 mm in an approved random pattern. The Engineer may, however, require a different
random pattern or equal spacing of the tines during the course of the work, and provision shall be
made to supply different sets of combs as required. No additional payment will be made for the first
two changes in the spacing of the tines.
The combs for applying the texturing shall be at least 3.0 m wide. It must also be possible to adjust the
combs to a lower position in order to compensate for wear.
(iii) Burlap-Drag-and-Grooved Texture

This texture shall be obtained by first applying a burlap-drag finish to the concrete surface and then by
grooving it with a grooving comb.
The first pass of the burlap drag shall be made as soon as construction operations permit and before
the wet sheen has disappeared from the surface. Burlap dragging shall be repeated until a gritty and
uniform texture having the required depth of texture has been obtained.
Every morning the burlap drag shall be wetted and kept moist throughout the day. At the end of each
day's pour the burlap mats shall be cleaned or discarded and replaced with new burlap if cleaning is
not possible.
After the concrete has hardened, all loose particles generated by the cutting of the grooves shall be
broomed off the surface with stiff hand brooms or mechanically operated rotary brooms.
When measured with a suitable depth gauge, the grooves shall be not less than 2 mm and not more
than 4 mm in depth.
The Engineer may permit the use of texturing equipment other than the grooving comb, provided that it
produces a texture similar to that produced by the metal tines.
(c) Hand texturing

Texturing the surface with hand-held brooms or combs shall be allowed only where the pavement is so
small or irregular, or the site is so restricted as to make the use of the texturing machine impracticable,
or in cases of mechanical breakdown of the texturing machine, in which case it may be used for the

required texturing of concrete already placed. The brush or comb to be used then shall be of the same
type and width used in the machine.
In order to ensure straight grooves, the comb shall be operated against a straight-edge placed at right
angles to the pavement centreline.
The same requirements regarding groove dimensions or texture depth as for machine-texturing will
apply.
7111 Curing
The exposed surfaces, including the sides of the slab, shall be treated immediately after the required
texturing of the surface has been effected and after the side formwork has been removed by the
application of a white-pigmented curing compound as specified in sub-clause 7102(h) in accordance
with the directions of the manufacturer.
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The curing compound shall be sprayed onto the surface at a rate of 0.35 litre/m or as approved by the
Engineer by means of a mechanical distributor capable of producing a fine fog-type of spray, which will
not damage the surface of the concrete. The curing compound shall be applied in two layers with the
distributor moving in opposite directions for the two applications. Coverage shall be uniform over the
entire surface and the rate of application of the curing compound shall be carefully controlled.
During spraying operations, the curing compound shall be continuously stirred mechanically to keep
the pigmentation in suspension. The spray nozzles shall be adequately protected against wind.
After shutting off the spray nozzles, no dripping of curing compound on the concrete surface may
occur. If necessary, the Contractor shall provide drip pans suspended below the nozzles to prevent
dripping of the curing compound onto the pavement.
The curing membrane shall be maintained intact for at least seven (7) days after the concrete has
been placed. Any damage to the curing membrane, caused by the Contractor's activities, shall be
repaired by hand-spraying the affected areas.
Areas inaccessible to the mechanical distributor such as irregular shaped areas, or those with varying
widths or shapes, shall be sprayed with curing compound by means of approved hand spraying
equipment, at the specified rate of application.
7112 Transverse Joints
(a) General
Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and shall be
contraction, expansion or warping joints at the spacings shown on the Drawings or as specified in the
Transverse joints shall be straight within the following tolerances along the intended line of the joint,
which is the straight line transverse to the longitudinal axis of the carriageway except where otherwise
shown on the Drawings:
 Deviations of the filler board or bottom crack inducer from the intended line of the joint shall
not be greater than ± 10 mm;
 The best fit straight line through the joint groove as constructed shall not be more than 25 mm
from the intended line of the joint;
 Deviations of the joint groove from the best fit straight line of the joint shall not be greater than
10 mm.

Transverse joints on each side of a longitudinal joint shall be in line with each other and of the same
type and width.
Concrete pavement layers shall be isolated from fixed structures by expansion joints; or earthworks or
a granular layer over the structure; or by bridge-type expansion joints; or by lengths of fully flexible
pavement construction. End of pavement surface slabs shall have a transition bay as shown on the
Drawings, leading into the fully flexible construction.
(b) Contraction joints

Contraction joints shall consist of:
 A sawn joint groove;

 Dowel bars; and
 A sealing groove.
(c) Expansion joints

Expansion joints shall consist of:
 A joint filler board;

 Dowel bars; and
The filler board shall be positioned vertically within the prefabricated joint assemblies along the line of
the joint within the tolerances given in sub-clause 7112(a) and at such depth below the surface as will
not impede the passage of the finishing beams on the paving machines.
The joint filler board together with the sealing groove shall provide a complete separation of adjacent
slabs and any spaces around dowel bars and between the layer underlying the slab. The filler board
shall be packed with a suitable compressible material after fixing the joint assembly.
(d) Warping joints

Warping joints shall consist of:
 A sawn groove;
 Tie bars; and
(e) Construction joints

Construction joints made at the end of a working day in unreinforced concrete slabs and jointed
reinforced concrete slabs shall be contraction joints. In the event of mechanical breakdown of the
concreting machinery, or at the onset of adverse weather, emergency joints may be formed.
Emergency joints in unreinforced concrete slabs shall be contraction joints not less than 2.5 m from
the preceding or succeeding joint position.
Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the preceding
or succeeding joint position. The stop end formwork shall be sufficiently rigid to ensure that dowel
bars, tie bars or reinforcement will be held in position in compliance with the Specification, and placed
in such a position that it permits the longitudinal reinforcement to project through the joint for a
distance of at least 750 mm.

Construction joints in continuously reinforced concrete slabs at the end of the day or in an emergency
shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement. The stop-end
formwork shall be sufficiently rigid to ensure that the longitudinal reinforcement and the tie bars, which
project through the joint, are held in the correct position.
7113 Longitudinal Joints
(a) General
Sawn or wet-formed longitudinal joints shall be provided in surface slabs at the positions as shown on
the Drawings. Generally, bay widths are not to be greater than 4.2 m (5.0 m with limestone aggregate)
for unreinforced slabs, or 6 m (7.6 m with limestone aggregate) for reinforced concrete surface slabs
with transverse reinforcement.
Wet-formed longitudinal joints shall consist of wet-formed joint grooves, a bottom crack inducer and tie
bars except where transverse reinforcement is permitted in lieu.
Longitudinal joints shall be constructed within the following tolerances:
 Deviations of the bottom crack inducer from the intended line of the joint, parallel to the axis of
the road shall be not greater than  13 mm;
 The joint groove shall be located vertically above the bottom crack inducers within a horizontal
tolerance of  25 mm;
 The best fit line along the constructed joint groove shall be not more than 25 mm from the
intended line of the joint;
 Deviations of the joint groove from the best-fit line of the joint shall not be greater than 10 mm.
 Sawn longitudinal joints shall consist of joint grooves.
Tie bars may be replaced by continuous transverse reinforcement across the joints in continuously
reinforced concrete slabs which are constructed in more than one lane width in one operation,
provided that the transverse reinforcement is a minimum of 12 mm diameter bars at 600 mm centres.
The transverse reinforcement in these circumstances shall be protected by suitable bituminous paint
or equivalent coating for a distance of at least 75 mm either side of the joint.
(b) Longitudinal construction joints

Longitudinal construction joints between separate slabs shall have tie bars with a joint groove.
Alternatively, if split-forms are used, the transverse reinforcement, if 12 mm diameter or more, may be
continued across the joint for a minimum of 500 mm or 30 times the diameter of the transverse
reinforcement bars, whichever is the greater. The transverse reinforcement in these circumstances
shall be protected by suitable bituminous paint or equivalent coating for a distance of at least 75 mm
either side of the joint. Where the edge of the concrete slab is damaged, it shall be made good before
the adjacent slab is constructed.
7114 Joint Grooves
(a) General
Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
Transverse joint grooves, which are initially constructed less than the full width of the slab, shall be
completed by sawing through to the edge of the slab and across longitudinal joints as soon as any
forms have been removed and before an induced crack develops at the joint.

(b) Sawn transverse and longitudinal joint grooves

Sawing shall be undertaken as soon as possible after the concrete has hardened sufficiently to enable
a sharp edged groove to be produced without disrupting the concrete and before random cracks
develop in the slab.
The grooves shall be between ¼ and ⅓ of the specified depth of the slab and of any convenient width
not less than 3 mm.
The sealing groove may be sawn to the required width later. Expansion joint sealing grooves shall be
sealed as soon as practical after sawing.
(c) Wet-formed longitudinal joint grooves

When slabs are constructed in more than one lane width in one operation, a joint groove shall be
formed by inserting a groove-former ahead of the finishing beams from a dispenser. The concrete so
displaced shall be re-compacted by a vibrating compactor or similar device, at least 300 mm wide
operating symmetrically along the line of the joint.
After finishing the concrete, the groove-forming strip shall be in the correct position and alignment,
within 10º of the vertical, and to sufficient depth below the surface to allow for the passage of the
finishing beam within the range of 0-3 mm below the finished level of the slab. Groove-forming strips in
wet-formed longitudinal joint grooves shall be left in place.
(d) Construction joint grooves in surface slabs

The grooves shall be formed by fixing a groove-former; or strip or cork seal; along the top edge of the
slab already constructed, before concreting the adjacent slab.
Where the edge of the concrete is damaged, it shall be ground or made good before fixing the groove-
forming strip.
Alternatively, the subsequent slab may be placed adjacent to the first and a sealing groove sawn later
in the hardened concrete to the minimum depth specified or to the manufacturer’s instructions if
greater, and to sufficient width to eliminate minor spalling of the joint arris, up to a maximum of 25 mm
for longitudinal joints and 40 mm for transverse joints. The joint shall be sealed in compliance with
Clause 7116.
(e) Groove formers and bottom crack inducers

Except where joint grooves are sawn, a bottom crack inducer shall be provided at each longitudinal
joint position. The bottom crack inducer shall be triangular or inverted Y-shaped fillet, with a base
width not less than the height, made of timber or rigid synthetic material. It shall be firmly fixed to the
sub-base so as to remain in position during the whole process of constructing the slab.
The combined depth of groove-formers and bottom-crack inducers shall be between ¼ and ⅓ of the
depth of the slab and the difference between the depth of the groove-former and the height of the
bottom-crack inducer shall not be greater than 20 mm.
Groove-forming sealing strips for wet-formed longitudinal joints shall be inserted continuously along
the joint.

7115 Tie Bars and Dowels
(a) General
Dowels and tie bars shall be placed across joints where indicated, correctly aligned, and securely held
parallel to the surface of the finished pavement, such that after placement they remain in their
specified location. The spacing and vertical location of dowels and tie bars shall be as detailed except
where the planned spacing cannot be maintained because of form length or interference with form
braces. In such cases, closer spacing with additional dowels or tie bars shall be used.
All reinforcement, dowels and tie bars shall be clean and free of oil, grease, loose rust and other
foreign material when the concrete is placed. Paint the free portions of the dowels, including ends, with
two coats of bituminous emulsion. The unpainted portions of dowels shall be installed in the initially
placed concrete slab.
Dowels installed in contraction joints during paving operations shall be held securely in position by
means of rigid metal frame cradles to prevent them from rising, sliding out or becoming distorted under
paving operations.
Dowels and tie bars in fixed-form paving shall be placed by the bonded-in-place method. Installation
by removing and replacing dowels and tie bars in preformed holes, including their withdrawal to assist
in form stripping, will not be permitted.
(b) Tie bars

Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid assemblies
with adequate supports and fixings to remain firmly in position during the construction of the slab.
Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from above using
a method which ensures re-compaction of the concrete around the tie bars.
At longitudinal construction joints, tie bars may be adequately fixed to side-forms or inserted into the
side of the slab by a method which ensures re-compaction of the concrete around the tie bars; and
adequate bond.
Tie bars in warping joints shall be positioned from the top surface of the slab within +20 to -10 mm of
the mid depth of the slab.
Tie bars in other joints shall be positioned and remain within the middle third of the slab depth,
approximately parallel to the surface and approximately perpendicular to the line of the joint, with the
centre of each bar on the intended line of the joints within a tolerance of 50 mm; and with a minimum
cover of 30 mm below any top crack-inducer of joint groove for slabs 200 mm thick or more; or 20 mm
for slabs up to 200 mm thick.
At transverse construction joints in continuously reinforced concrete, tie bars shall be fixed at twice the
normal spacing midway between the longitudinal reinforcement bars so that 750 mm extends each
side of the joint at the same level as the longitudinal reinforcement and be tied to the transverse
reinforcement. Where paving from a construction joint is not resumed within 5 days, an extra
longitudinal reinforcement bar 8 m long shall be lapped and tied to each tie bar. These extra bars may
be combined with the tie bars. Where the spacing between longitudinal reinforcement and the extra
8 m long bars is less than 90 mm, the nominal size of aggregate shall be 20 mm for a sufficient
number of concrete batches to complete that section of pavement.
Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be placed
at the same level as the transverse reinforcement and tied to the longitudinal reinforcement.

(c) Dowels
Dowel bars shall be rigidly supported both in vertical and horizontal alignment, on cradles in
prefabricated joint assemblies positioned prior to construction of the slab. For contraction joints, as an
alternative to prefabricated assemblies, dowel bars may be mechanically inserted with vibration into
the concrete by a method, which ensures full re-compaction of the concrete around the dowel bars,
and the surface finished by a diagonal finishing beam, or a longitudinal oscillating float travelling
across the slab.
Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm. They shall be
aligned parallel to the finished surface of the slab, to the centreline of the carriageway and to each
other within the following tolerances after construction of the slab:
 All bars in a joint shall be within ± 6 mm per 300 mm length of bar;

 Two-thirds of the bars shall be within ± 4 mm per 300 mm length of bar;
 No bar shall differ in alignment from an adjoining bar by more than 6 mm per 300 mm length
of bar in either the horizontal or the vertical plane;
 Bars shall be equally positioned about the intended line of the joint within a tolerance of
25 mm.
Cradles supporting dowel bars shall not extend across the line of the joint.
7116 Sealing of Joint Grooves
(a) General
All transverse joints in surface slabs, except for construction joints in continuously reinforced concrete
slabs shall be sealed using one of the joint seals described in sub-clause 7102(f). Additionally,
longitudinal joints, which are sawn or widened, shall be sealed.
(b) Preparation of Joint Grooves for Sealing

That part of the groove-former used to form the sealing groove or any temporary seal shall be
removed cleanly without damaging the joint arrises to a minimum depth of 25 mm where compression
seals are used; or otherwise to such depth as will provide an applied seal to the dimensions shown in
the Drawings after allowing for any necessary caulking material.
If joint grooves are not initially constructed to provide the minimum dimensions for the joint seals as
given in the Drawings, they shall be widened by sawing. Joint grooves formed by tapered formers
need not be widened. The sealing grooves shall be cleaned out immediately after sawing using high-
pressure water jets to remove all slurry from the joint before the slurry hardens.
If rough arrises develop when grooves are made, they shall be ground to provide a chamfer 5 mm
wide. If the groove is at an angle up to 10º from the perpendicular to the surface, the overhanging
edge of the sealing groove shall be sawn, or ground perpendicular. If spalling occurs or the angle of
the former is greater than 10º the joint sealing groove shall be sawn wider and perpendicular to the
surface to encompass the defects up to a maximum width, including any chamfer, of 40 mm for
transverse joints and 25 mm for longitudinal joints.
For applied sealants, the sides of the joint sealing groove shall be scoured by dry abrasive blasting.
This shall not be carried out before the characteristic compressive strength of the concrete is expected
to reach 15 MPa. When compression seals are used, the sides of the groove may be ground or wire
brushed.

For hot and cold applied sealants, compressible caulking material, de-bonding strip or tape or cord
compatible with the sealant, of a suitable size to fill the width of the sealing groove, shall be firmly
packed or stuck in the bottom of the sealing groove to such a depth so as to provide the correct depth
of seal as shown in the Drawings with the top of the seal at the correct depth below the surface of the
concrete.
All groves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free compressed
air. The groove shall be clean and dry at the time of priming and sealing.
For applied sealants, the joint grooves shall be primed with the relevant primer for the hot or cold
applied sealant in accordance with the manufacturer’s recommendations. When necessary, the joint
grooves may be primed and sealed earlier than 14-days after construction, as soon as the grooves
have been grit-blasted and cleaned.
(c) Sealing with applied sealants

Sealing shall be carried out continuously along the full length of joint in any one rip, except for
remedial areas. When hot or cold applied sealants are used, the sealant shall be applied within the
minimum and maximum drying times of the primer recommended by the manufacturer. Priming and
sealing with applied sealants shall not be carried out when the naturally occurring temperature in the
joint groove to be sealed is below 10ºC, except that between 8ºC and 10ºC, it may be carried out when
the temperature is rising.
Hot-applied sealants shall be heated in and applied from a thermostatically controlled, indirectly
heated dispenser with a recirculating pump. The sealant shall not be heated to a temperature higher
than the safe heating temperature nor for a period longer than the safe heating period, both as
specified by the manufacturer. The dispenser shall be cleaned out at the end of each day and
reheated material shall not be used.
The components of cold-applied sealants shall be thoroughly mixed in the correct proportions in an
automatic metering and mixing dispenser or, for hand application, using a power-operated paddle
mixer for sufficient time to produce a homogenous mix and without entrapped air. As soon as possible
after mixing and within the work life of the sealant, the material shall be dispensed into the joint, or
applied using a caulking gun, to the concrete below the concrete surface. The tack-free time shall be
achieved within 3 hours for machine dispensed material, or within 12 hours for hand applied material.
(d) Sealing with compression seals

When compression seals are used, the widths of the seal shall be selected in relation to the width of
the sealing groove, the bay lengths and the manufacturer’s recommendations so that the estimated
maximum width of the joint opening shall be not more than 70% of the original width of the seal, the
estimated maximum width being calculated on the basis of a movement of 4 mm per 10 m run of slab.
The maximum calculated width of sealing groove shall be 30 mm. The depth of groove shall be such
that the contact face of the seal shall be a minimum of 3 mm below the surface of the concrete.
Compression seals shall be inserted into the grooves without prior extension or rotation and, where
recommended by the manufacturer, with a lubricant adhesive which is compatible with the seal and
the concrete. The adhesive shall be applied to both sides of the sealing groove or the seal, or to both.
The seal shall be positioned with its axis perpendicular to the concrete surface. Excess adhesive on
top of the seal shall be removed to prevent adhesion of the top faces of the seal under compression.
Except when compression seals are used in longitudinal joints, the transverse joint seal shall be
continuous across the slab and the longitudinal joint groove forming strips shall be cut to the required
depth after the concrete has hardened for the transverse seal to be inserted. If compression seals are
used in longitudinal joints where the grooves have been sawn after construction of the slab, they shall

be continuous across transverse joints, with the transverse seals butted and fixed to the longitudinal
seals with adhesive.
7117 Trial Pavement
(a) General
When commencing with paving operations, the Contractor shall construct a trial section of pavement,
in a position approved by the Engineer, to demonstrate the capability of the Contractor to construct the
pavement in accordance with the Specifications.
The trial section shall be constructed with the same materials, concrete mix, plant and equipment as
those intended for use by the Contractor for the pavement; and the Contractor shall also demonstrate
the methods proposed for use in applying the required surface texture; constructing the construction of
joints; placing of tie-bars and, dowels; and all other operations to be used in the construction of the
pavement in accordance with the Specifications.
Before the Contractor commences with the construction of the trial section, he shall demonstrate to the
Engineer that all items of his paving equipment are in a satisfactory working order.
An initial trial section of not less than 150 m in length for mechanical construction, and at least 30 m in
length for manual construction, shall be constructed in one continuous operation and be submitted for
approval.
The Engineer shall also be entitled to call for a new trial section to be constructed at any stage of the
contract when changes by the Contractor in the approved equipment, materials, mix or rate of paving
warrant the construction of another trial section.
The Contractor will be paid for the actual length of trial pavement constructed as an initial trial section
and trial sections constructed in consequence of changes in mixes, techniques, equipment and
materials, effected by the Contractor, up to a maximum total length of 300 m for mechanical
construction, and 60 m for manual construction. In addition, the Contractor will be paid for any trial
lengths necessary as a result of similar changes required by the Engineer, notwithstanding the fact
that the trial section built by the Contractor complied with the specified requirements.
(b) Further trial sections and permission to start constructing the pavement
The Contractor may, unless advised of any deficiencies in the trial section, proceed with the
construction of the pavement ten (10) days after the completion of the trial section or such earlier time
as the Engineer may determine.
In the event of deficiencies in the trial section, the Engineer may order the Contractor to construct a
further trial section, which will again be regarded as the initial trial section. The Contractor may then
proceed with the construction of the pavement ten (10) days after the satisfactory completion of the
second or subsequent trial section.

The Construction tolerances shall be as specified under Division 10100 of these specifications.
7119 Process Control

The Contractor shall conduct a sufficient number of tests necessary for ensuring compliance with the
requirements specified in this Division during all phases of the work.

Accelerated early compressive-strength shall be conducted regularly with a view to predicting the 28-
day compressive strength of the concrete. Test procedures and methods for the prediction of 28-day
compressive strength shall be determined in consultation with the Engineer.
Where the accelerated tests indicate that the required 28-day compressive strengths will not be
attained, the Contractor shall immediately effect the necessary changes to the materials and/or mix
proportions in order to ensure that further work will comply with the requirements.
7120 Quality Control and Workmanship
(a) General
Routine inspection and testing shall be carried out by the Engineer to determine whether the quality of
materials and workmanship complies with the requirements of this Division.
The assessment of test results and measurements, and the acceptance of the work, shall be done in
accordance with a procedure developed by the Engineer.
The following sub-clauses shall also apply.
(b) Compressive-strength control

The Engineer may, at his discretion, decide to use the Contractor's test results in the acceptance plan,
if he is satisfied that the Contractor has complied with all the process control requirements.
(c) Relationship between the Compressive and Flexural Strengths of Concrete

The relationship between the 28-day compressive and the 28-day flexural strengths of the concrete
established by the preliminary tests shall be monitored during paving operations by regular tests at the
discretion of the Engineer.
For this purpose, sets of three samples each for both flexural and compressive strength tests shall be
manufactured from the same batch of concrete and tested for flexural and compressive strength
respectively.
If the test results indicate a relationship which deviates from that established by the preliminary tests,
the specified compressive strength, as specified in sub-clause 7102(j) shall be adjusted accordingly.
(d) Air Content of Concrete

If any test for air content shows a value falling outside the specified limits, the quantity of air-entraining
agent added to the concrete mix shall be adjusted, until the air content of the concrete is within the
specified limits.
(e) Unacceptable Work or Materials

Any work or materials which do not comply with the specified requirements shall be removed and
replaced with work or materials which comply with the requirements or, if the Engineer so permits shall
be repaired as specified in Clause 7121, so that it shall comply with the specified requirements after
having been repaired.
(f) Acceptance of Concrete of Inferior Strength or Thickness at Reduced Payment

In lieu of requiring the removal of work that has been rejected on account of insufficient strength or
thickness, the Engineer may accept such work, at his sole discretion, at reduced payment for the
pavement concrete, on the following conditions:
 Where concrete is deficient in thickness or in strength, the reduced payment shall be

calculated in accordance with the following formula:

(𝑑𝑤) (𝑓𝑤)
P= 𝑥 100 ……………………………………………Equation 1
(𝑑𝑠) (𝑓𝑠)
where:
P = percentage of normal compensation
dw = actual average thickness of slab
ds = specified average thickness of slab
fw = actual 28-day compressive strength of slab (average of 28-day compressive-strength tests)
fs = specified 28-day compressive strength of slab
 The concrete pavement shall be subject to rejection when the average thickness is less than
93% of the specified thickness or the strength is less than 91.5% of the specified compressive
strength, as determined for the parameters used in equation 1.
 Where both thickness and strength are deficient, it will be rejected if P is less than 70%.
 Where P exceeds 100%, normal compensation only will be payable.
7121 Remedial Work (Rehabilitation)

In addition to the requirements specified in Clause 1208, the following shall apply specifically to
concrete pavements:
(a) Removing concrete

Where any section of the pavement which does not comply with the specified requirements is to be
removed and reconstructed, the entire portion of the slab shall be removed and reconstructed as
prescribed by the Engineer in writing.
(b) Removing high spots

Where the Engineer so permits, high spots may be removed by approved power chisels and planers.
After the high spots have been removed, the Contractor shall, if required, grind the surface up to the
nearest longitudinal and transverse joint in order that all the ground areas will be neat rectangular
areas with a uniform texture.
On all portions of the pavement where the surface texture has been destroyed or reduced in depth by
grinding, the surface texture shall be restored by grooves being cut into the concrete surface. The
grooves shall be of the same size and spacing as specified in sub-clause 7110(b).
(c) Repairing joints

Joints along which spalls occur that exceed 5 mm in depth at any point measured from the top surface
of the pavement, or any other joints, which in the opinion of the Engineer are unacceptable, shall be
repaired with an approved epoxy resin mortar. The method of repairing joints requires the prior
(d) Repairing cracks

The Contractor shall be responsible for constructing a pavement which will not exhibit any cracks.
Where cracks occur in the pavement which, in the opinion of the Engineer do not warrant the removal
and reconstruction of the particular section of pavement, the Contractor shall, if so required by the
Engineer, repair such cracks, in accordance with a method approved by the Engineer.
(e) Rehabilitation of concrete pavements

Where concrete pavements have to be widened or where long continuous sections of concrete
pavement have to be replaced and, in the opinion of the Engineer, the concrete can be placed with
pavers, the work shall be regarded as, and shall be measured and paid for as, new work under the
applicable items for new work.
(f) Removal of existing concrete

Where any section of the concrete pavement has to be removed, the whole panel between
longitudinal and transverse joints shall be removed, unless it is specified in the Specifications or
ordered by the Engineer that only part of the panel be removed. In such cases, the concrete shall be
removed either over the full length or over the full width of the panel between joints. Where the edge of
the section to be removed coincides with an existing joint, the edge shall be accurately demarcated in
a straight line and sawn with an approved concrete saw to a depth of at least 50 mm before the
removal of the concrete may commence.
Existing concrete may be broken up in any approved manner, but strict control shall be exercised to
ensure that the adjacent concrete is not damaged in any way. The Contractor shall repair any damage
to the adjacent concrete at his own cost in accordance with the instructions of the Engineer. Such
remedial work may involve the partial or complete replacement of the damaged panel should it be
deemed necessary by the Engineer.
Care shall be taken at existing joints to ensure that tie bars or dowels are not damaged or bent so as
to render them useless.
Broken-up concrete shall be removed to approved spoil dumps.
(g) Placing new concrete

Before concrete is placed, the underlying surface or layer shall be prepared as specified.
Except where concrete is placed in continuous lengths exceeding 50 m, placing, compacting and
finishing with hand equipment shall be carried out as specified in Clause 7108. Where new concrete is
placed next to existing concrete, the edge of the existing pavement shall be properly cleaned and all
bituminous and other jointing material shall be removed.
Where various adjacent panels are constructed, the concrete in every alternate panel shall first be
placed. The concrete in the rest of the panels may be placed only after the concrete in the first panels
has sufficiently hardened so that no damage will be done to the first panels during construction
activities. All formwork shall remain in position for at least 24 hours.
(h) Surface texture

Unless otherwise specified in the Particular Specifications, the Contractor shall produce a surface
texture on the new concrete panels which shall be the same as that on the existing panels.
(i) Joints, tie bars and dowels

Joints shall be shaped and tie bars and dowels shall be placed where indicated on the Drawings and
as specified in Clauses 7112 up to and including 7116.
At joints in new concrete, the tie bars and dowels in the existing concrete shall be cleaned, and the tie
bars shall be straightened, should any such bars be indicated on the Drawings.
In regard to bent dowels, the Contractor shall follow the instructions of the Engineer. Before concrete
is placed, all the bars shall be accurately aligned as indicated on the Drawings and specified in Clause
7115. Where the sliding end of a dowel occurs in existing concrete, the dowel shall be extracted,
cleaned and treated in accordance with Clause 7115 prior to it being reused.
Where tie bars or dowels are shown on the Drawings at joints between existing and new concrete, but
no such bars occur in the existing concrete, holes shall be drilled in the existing concrete and fresh

bars placed and fixed as prescribed in the Particular Specifications or instructed by the Engineer. In
such cases, the dowels shall be placed with their sliding ends in the new concrete.
Where no bars are required between the existing and new concrete but such bars do occur in the
existing concrete, such bars shall be cut off flush with the concrete edge.
All joints between the existing and new concrete shall be sawn after the new concrete has hardened
sufficiently to prevent splintering or other damage from occurring. Sawing the joints may normally be
done from two (2) to five (5) days after the placing of the concrete. The width and depth of the sawn
grooves shall comply with the requirements set in the Particular Specifications and on the Drawings.
(j) Repairing joints and cracks in existing concrete pavement

Repairing the joints and cracks in the existing concrete pavement shall be done in accordance with the
requirements set out in the Particular Specifications and on the Drawings, and as required by the
Engineer.
(k) Retexturing
Where in the opinion of the Engineer the skid resistance of the concrete pavement surfaces is too low,
or the texture is too irregular, and where so specified in the Particular Specifications, such surfaces
shall be provided with a fresh texture.
The depth of texture and groove spacing shall comply with the requirements of the Particular
Specifications. The work shall be done with approved sawing equipment.

No vehicle with an axle load exceeding 20 kN shall travel over the completed surface within +14 days
after it has been completed, or such longer period as may be directed by the Engineer.

The rates tendered for the payment items of Division 7100 shall include full compensation for work in
restricted areas or for work requiring hand placing.
Item 71.01 Concrete trial pavement (thickness indicated)

(a) Mechanical construction ........................................................................... square metre (m²)
(b) Manual construction.................................................................................. square metre (m²)
The unit of measurement for the trial pavement shall be the square metre of completed trial section.
Not less than 150 metre of mechanically constructed trial pavement and not less than 30 metre of
manually constructed trial pavement will be measured for payment in line with the requirements of
Clause 7117.
 Materials and attendance for sampling and testing carried out by the Engineer;
 Protection of mixed material in transit and while awaiting tipping;
 Waterproof membrane underlay;

 Longitudinal, expansion, contraction, warping, and construction joint assemblies, including

joint filler and crack inducers, tie and dowel bars, dowel bar caps and bond breaking
compound;
 Formwork as item coverage in Pay Item 82.01, 82.02, 82.03 and 82.04;
 Mixing, laying spreading, compaction and finishing;
 Air entrainment;
 Reinforcement;
 Drilling and testing cores;
 Forming or sawing grooves, cleaning, caulking, temporary and permanent sealing of joints;
 Forming recesses, openings and bays;
 Cleaning existing joints where new concrete has to join up with existing work, for straightening
existing dowels and tie bars, and for cutting off existing bars;
 Shaping to falls;
 Additional width to suit requirements of equipment.
Item 71.02 Concrete pavement (thickness indicated)

(b) Manual construction ................................................................................. square metre (m²)
The unit of measurement shall be the square metre of concrete pavement placed and finished in
accordance with these Specifications and the Particular Specifications.
The quantity shall be calculated from the authorised dimensions of the completed surface, except
when the Engineer requires or the Drawings show local deviations from the specified thickness, such
as at bridge approach slabs. The volume of concrete in such cases shall be converted into an
equivalent area in square metres based on the specified thickness of the slab.
The tendered rate shall include the following specific requirements specific requirements:
 Trial mixes;
 Longitudinal, expansion, contraction, warping, and construction joint assemblies, including
joint filler and crack inducers, tie and dowel bars, dowel bar caps and bond breaking
compound;
 Air entrainment;
 Reinforcement;
 Forming or sawing grooves, cleaning, caulking, temporary and permanent sealing of joints;
 Forming recesses, openings and bays;
Item 71.03 Texturing and curing the concrete pavement

(a) Burlap-dragged and grooved texture ........................................................ square metre (m²)
(b) Curing ....................................................................................................... square metre (m²)
The unit of measurement for texturing and curing shall be the square metre of completed pavement
which has received the specified surface texturing, and which was cured as specified. The quantity
shall be calculated from the specified horizontal dimensions of the completed concrete surface in the
case of texturing and from the specified horizontal dimensions of the completed concrete surface, plus
the surface area of the slab sides, in the case of curing.
The tendered rate for texturing shall include the following specific requirements:
 Trial mixes;
 Applying the specified surface texture.
The tendered rate for curing shall include the following specific requirements:
 Curing compound;
 Applying the specified curing agent
 Compensation for spraying the curing compound in unsealed joints after the sawing has been
completed.
Item 71.04 Variation in the rate of application of the curing compound .................... litre (l)
The unit of measurement in respect of increases or decreases in the rate of application of the curing
compound shall be the litre.
Payment for variations shall be made as specified in Clause 0103(g).
Item 71.05 Joints

(a) Expansion joints complete (excluding dowels) ............................................ linear metre (m)
(b) Longitudinal hinge joints: Sealed hinge joints (type indicated with reference to Drawings) ..
..................................................................................................................... linear metre (m)
(c) Longitudinal hinge joints: Unsealed hinge joints (type indicated with reference to Drawings)
.................................................................................................................... linear metre (m)
(d) Longitudinal hinge joints: Hinge joints between existing and new concrete in remedial/
rehabilitation work ........................................................................................ linear metre (m)
(e) Sealed transverse contraction joints sawn in two separate operations (widths as shown on the
Drawings). .................................................................................................... linear metre (m)
(f) Dowel bars (mild steel) (diameter and length indicated): Installed in new concrete ............
.......................................................................................................................... number (No)
(g) Dowel bars (mild steel) (diameter and length indicated): Installed in existing concrete in
rehabilitation work. ........................................................................................... number (No)
(h) Tie-bars (diameter and length indicated): Installed in new concrete ............... number (No)
(i) Tie-bars (diameter and length indicated): Installed in existing concrete in

remedial/rehabilitation work. ............................................................................ number (No)

(j) End caps for dowels at expansion joints ........................................................... number (No)
(k) Forming and sealing the joints between asphalt and concrete pavements linear metre (m)
(l) Cleaning of tie-bars and dowels in existing concrete pavement and straightening tie-bars in
existing concrete pavement in remedial/rehabilitation work .............................. number (No)
The unit of measurement for joints in the pavement shall be the metre of completed joint, except that
dowel bars and tie-bars across joints shall be measured separately by the numbers of each type
installed.
Construction joints shall not be measured for payment and their cost shall be deemed to be included in
the rate tendered for the concrete pavement. However, if the position of a longitudinal construction
joint coincides with that of a hinge joint, the Contractor shall be paid at the rate tendered for the type of
hinge joint replaced by the construction joint, provided that the requisite number and sizes of tie bars
for the hinge joints are installed. Where the hinge joint replaced by the construction joint is a sealed
hinged joint, the construction joint shall be sawn and sealed, in which case the Contractor will be paid
at the tendered rate for sawn and sealed hinge joints.
The tendered rate for expansion joints shall include the following specific requirements:
 Forming the joint;

 Joint filler, rounding or chamfering the corners;
 Installing a compression seal.
The tendered rate for longitudinal hinge joints shall include the following specific requirements:
 Sawing the joint (if required);

 Inserting the seal (if required).
The tendered rate for transverse contraction joints shall include the following specific requirements:
 Sawing the joint and installing the specified type of seal;

 Appurtenant materials;
 Temporarily sealing the joint with paper rope.
The tendered rate for dowel bars and tie-bars shall include the following specific requirements:
 Supplying, cutting, placing, holding the bars in position;

 Supporting framework or cradles;
 Fixing the end caps and bond breaking materials to dowels.
The tendered rate for forming and sealing the joints between asphalt and concrete pavements shall
include the following specific requirements:
 Supplying all the necessary plant and materials;

 Forming a joint;
 Cleaning and sealing.
Item 71.06 Drilling and testing of cores

(a) 100 mm cores drilled from the pavement .......................................................... number (No)
(b) 150 mm cores drilled from the pavement and tested for compressive strengthnumber (No)
The unit of measurement shall be the number of cores drilled or drilled and tested on the instruction of
the Engineer. Cores drilled by the Contractor at his own initiative as part of his process control or for
testing cracks sealed at the Contractor's own cost, will not be measured for payment.
 Drilling the test cores;

 Tests at an approved laboratory and other incidentals;
 Restoring the concrete pavement where holes were drilled.
Item 71.07 Steel reinforcement in concrete pavement

(a) Mild steel bars (grade specified) ............................................................................. tonne (t)
(b) High tensile steel bars (grade specified) ................................................................ tonne (t)
(c) Welded steel fabric .......................................................................................... kilogram (kg)
The unit of measurement for steel bars shall be the tonne of reinforcing steel in place in accordance
with the Drawings or as authorised.
The unit of measurement for welded steel fabric shall be the kilogram of welded steel fabric in place in
the special panels of concrete paving which require reinforcement, the quantity of which shall be
calculated from the area of the mesh used in accordance with the Drawings or as authorised by the
Engineer.
Item 71.08 Removing existing concrete in remedial/rehabilitation work

(a) Concrete without reinforcement................................................................. cubic metre (m³)
(b) Reinforced concrete.................................................................................... cubic metre (m³)
The unit of measurement shall be a cubic metre of concrete broken up and removed to approved spoil
dumps as specified. The quantity shall be determined in accordance with the authorised horizontal
dimensions and the average depth of the part removed.
The tendered rate shall include the following specific requirement:
 Haulage for the disposal of material.
Item 71.09 Sawing existing concrete in remedial/rehabilitation work .... square metre (m²)
The unit of measurement shall be a square metre of saw-cut in the existing concrete as approved by
the Engineer and sawn to the required depth, measured once only, irrespective of the number of times
the sawing has to be repeated to obtain such depth. The quantity shall be the product of the
authorised length and depth of the saw-cut.
 Demarcating the saw line;

 Providing and applying water and other material;
 Sawing the concrete.
Item 71.10 Removing existing pavement layers in remedial/rehabilitation work

(a) Un-cemented material ................................................................................ cubic metre (m³)
(b) Cemented material ..................................................................................... cubic metre (m³)
(c) Cemented crushed stone ........................................................................... cubic metre (m³)

The unit of measurement shall be a cubic metre of material excavated and removed. The quantity
shall be computed in accordance with the authorised dimensions for the excavation. The classification
of the material shall be made in accordance with the provisions of Division 5300.
 Excavation;
 Haulage;
 Disposal;
Item 71.11 Re-compaction of underlying pavement layers of gravel (Required density stated)
in remedial/rehabilitation work .................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of material reprocessed and compacted. The
quantity shall be calculated in accordance with the authorised dimensions of the layer.
 Breaking up the layer;

 Compacting and finishing;
 Preparing the layer for placing the concrete.
Item 71.12 Remedial/Rehabilitation work: Reconstructing underlying pavement layers with:

(a) Gravel material ............................................................................................cubic metre (m³)
(b) Crushed stone .............................................................................................cubic metre (m³)
(c) Asphalt.........................................................................................................cubic metre (m³)
The unit of measurement shall be a cubic metre of underlying pavement layer reconstructed. The
quantity shall be computed in accordance with the authorised dimensions.
 Preparing foundation;
 Procuring and placing the material;
 Transporting (any distance).
Item 71.13 Extra over item 71.12 for stabilisation of underlying pavement layers under
reconstruction:
(a) Chemical stabilisation of gravel layers ........................................................cubic metre (m³)
(b) Chemical stabilisation of crushed-stone layers ...........................................cubic metre (m³)
(c) Bituminous stabilisation of crushed-stone layers ........................................cubic metre (m³)
The tendered rate shall include full compensation for the additional costs for stabilising the material,
including mixing the material and the stabilising agent in the plant, curing the layer, and providing the
water and the curing agent. The provision of the stabilising agent will be paid for separately under sub-
item 71.14.
Item 71.14 Stabilising agents applied in remedial/rehabilitation work:

(a) Ordinary Portland cement ........................................................................................tonne (t)
(b) Anionic stable grade bitumen emulsion (60% net bitumen) ........................................ litre (l)
(c) Other chemical stabilising agents (type indicated) ...................................................tonne (t)

(d) Other bituminous stabilising agents (type and grade stated) ...................................... litre (l)
The provisions of Division 4500 shall also apply.
Item 71.15 Preparing the underlying layers after the concrete has been removed in
remedial/rehabilitation work:
(a) Chemically stabilised gravel or crushed-stone layer ................................ square metre (m²)
(b) Unstabilised crushed-stone layer ............................................................. square metre (m²)
(c) Asphalt sub-base ...................................................................................... square metre (m²)
The unit of measurement shall be a square metre of existing underlying layer prepared in accordance
with the requirements of Clause 7103. The quantity will be computed in accordance with the
authorised dimensions of the prepared layer.
 Preparation and procurement of materials;

 Trimming, watering and compacting;
 Haulage for disposal of surplus material;
 Protecting.
This item shall not apply to reconstructed or reprocessed layers.
Item 71.16 Placing fine asphalt and coarse slurry in preparing the underlying layers as
specified in Clause 6604 and 7106(d):
(a) Fine continuously graded asphalt for levelling the surface .................................... tonne (t)
(b) Coarse slurry for levelling the surface ........................................................ cubic metre (m³)
The unit of measurement for sub-item (a) shall be a tonne of asphalt placed in accordance with the
instructions of the Engineer.
The unit of measurement for sub-item (b) shall be a cubic metre of slurry placed in accordance with
the instructions of the Engineer.
 Procuring, placing, compacting and finishing;

 Haulage.
Item 71.17 Retexturing existing concrete pavement in remedial/rehabilitation work ..........

...................................................................................................... square metre (m²)
The unit of measurement shall be a square metre of existing concrete pavement, which has been
retextured.
 Preparation and texturing.
Item 71.18 Repairing joints and cracks in existing concrete pavement in

(a) Joints ........................................................................................................... linear metre (m)
(b) Cracks .......................................................................................................... linear metre (m)

The unit of measurement shall be a linear metre of joint or crack actually repaired on the instruction of
the Engineer and in accordance with the requirements of the specifications.
 Providing and applying all materials,

 Repairing complete.
Item 71.19 Drilling and placing dowels and tie bars in existing concrete in
(a) Dowels ............................................................................................................... number (No)
(b) Tie bars .............................................................................................................. number (No)
The unit of measurement shall be the number of bars placed in existing concrete at the joints with new
concrete.
 Cutting the bars;

 Drilling the holes in the existing concrete;
 Placing and fixing the bars with epoxy;
 Treating the sliding ends;
 Dowels.
Item 71.20 Re-treating existing dowels:

(a) Sliding end in existing concrete ......................................................................... number (No)
(b) Sliding end in new concrete .............................................................................. number (No)
The unit of measurement shall be the number of bars re-treated.
 Cleaning;
 Re-treating bars;
 Protecting.

Division 7200 Ultra-Thin Reinforced Concrete Pavement
7201 Scope
This Division covers all work in connection with providing materials for and constructing Ultra-Thin
Reinforced Concrete (UTRC) pavement, together with associated load transferring dowels and joint
sealing materials, laid to lines, levels and dimensions, as shown on the Drawings or directed by the
Engineer.
UTRC pavements should only be considered as an alternative surfacing for roads carrying relatively
low volume of traffic. Areas where UTRC shall be considered are:
 Surfacing of a new road or the rehabilitation/upgrading of an existing road;

 All traffic and road classes from low volume urban streets;
 Inlays;
 Federal and regional roads where traffic volumes are below 2 000 AADT with less than 5%
heavy vehicle;
 Areas of steep grades and stop/start heavy traffic;
 Areas where regular maintenance is unlikely.
7202 Material
(a) Cement
Cement used for concrete shall be Portland cement as specified in Sub-clause 7102(a).
Cement may be delivered in bags or in bulk.
(b) Concrete
Concrete shall have a minimum 28-day compressive strength of 30 MPa with a guidance mix
water:cement ratio of 0.45. Concrete mix proportions shall be calculated to suit the available materials
in order to meet the required compressive strength and slump requirements The use of low
water:cement ratios (e.g. <0.45), higher cement contents, plasticiser and high early-strength cement is
beneficial in minimising the risk of cracks.
(c) Concrete Aggregate

Concrete aggregates shall conform to the following:
 Aggregates from a single source shall be used in the Works unless specifically authorised by
the Engineer.
 The maximum soluble sulphate salt content of aggregates, expressed as percentage SO3 by
mass, shall not exceed 0.1%. Aggregates containing more than the maximum permissible
amount of sulphates, or with visible encrustation of salts, must be washed and drained before
being used in concrete. The Engineer may direct washing or re-washing of the aggregates
until he is satisfied that harmful quantities of salts are not present. All fine Aggregate shall be
free from injurious amounts of organic impurities.
 Fine aggregate shall be natural sand, manufactured sand, or a combination of natural and
manufactured sand, meeting the following requirements:
 Natural sand - shall be composed of clean, hard, durable, uncoated grains, free from lumps or
flaky particles, organic matter, loam, or other deleterious substances.
 Manufactured sand - shall be made from stone meeting all the quality requirements for coarse
aggregates.
 Fine aggregate- shall confirm to the gradation in Table 7202/1
Table 7202/1: Gradation of Fine Aggregate
Standard Sieve (mm) % Passing
9.5 100
4.75 95-100
2.36 80-100
1.18 50-85
0.600 25-60
0.300 10-30
0.150 1-10
0.075 0-3
 Coarse aggregate shall be nominal 9mm size and conform to the following requirements:
 It shall be clean, tough, durable gravel, crushed gravel, hard durable rock, metallurgical
furnace slag or gravel. It shall be free from soft, thin, elongated or laminated pieces. If
required, coarse aggregate shall be washed to produce a clean aggregate.
 Los Angeles Abrasion value shall not exceed 40%.
 The weighted loss shall not exceed 15% in the Sodium Sulphate Soundness test (AASHTO T-
104).
(d) Steel Reinforcement

The welded wire mesh reinforcing shall be Reference 200 (100 x 100 x 4mm) conforming to the South
African Standards SANS 1024-1991 and shall be supplied in sheets of 6 metres x 2.4 metres
(standard sheets).
Mesh in rolls shall not be used.
(e) Water
other substances injurious to the finished product. Water shall be tested in accordance with, and shall
meet the requirements of, AASHTO T 26.
Water known to be of potable quality may be used without test.

The following equipment, apparatus and special hand-tools shall be used:
 Formwork as item coverage in Pay Item 82.01, 82.02, 82.03 and 82.04 (50 x 50 mm steel box
sections, 2 m and 1 m);
 Vibrating beam screed of sufficient length to span shutters;
 Concrete saw fitted with a 10 or 8mm wide blade for cutting of joints;
 Concrete mixer of at least 250 litre capacity;
 Batching boxes or weighing apparatus;
 Wheelbarrows;
 Steel squeegees for spreading the concrete;
 Vibrating poker powered by electricity or portable generator;
 Tamping screed;

 Portable sun protection canopy if casting in direct sunlight and if ambient shade temperatures
are above 25ºC;
 Grooving rake;
 Plastic sheeting for covering concrete for curing;
 Equipment for sealing joints;
 Broom with extended handle for texturing the concrete.
(a) Preparation
The UTRC pavement shall be constructed on a previously prepared sub-base layer that has been
accepted by the Engineer.
In placing and fixing the side-forms, care shall be taken to check the vertical and horizontal alignment
of the formwork and to ensure that the side-forms are firmly and correctly placed before placing the
concrete. Once the side-forms have been placed, the levels must again be checked by placing the
straight edge across the tops of the side-forms and taking dip readings to ensure that the thickness of
the concrete will be within the tolerances shown in Table 7205/2.
The formwork shall be cleaned and oiled before use to ensure that it is easily removed. The length of
the side-forms shall not exceed 2 m. One metre side-forms shall be used to accommodate horizontal
curves and bends in the road.
Before commencing placing of the UTRC, all loose material must be removed from the surface and a
diluted stable grade anionic emulsion (diluted 1 part emulsion: 8 parts water) applied neatly and
uniformly to the surface. A course broom shall be used to evenly distribute the diluted emulsion,
leaving no pools of emulsion on the surface.
(b) Reinforcement
Care shall be taken in placing the mesh and ensuring that its proper location within the layer is
maintained, before and during the placing of the concrete, by installing suitably sized reinforcing
“chairs” to support the mesh.
The cover to the mesh shall be 25 mm and the mesh shall be laid butt jointed in both the longitudinal
and transverse direction with the overlap achieved by splicing the individual 5.6 mm bars of the mesh
with a 5.6 mm splice bar 400 mm long.
(c) Concrete
The concrete shall be uniformly placed with care being taken not to walk on or disturb the mesh
reinforcing; spread by means of steel squeegees; and finished to the level of the side forms or
adjacent concrete by means of a vibratory beam moved at a steady pace to produce a smooth finish.
After placement and compaction, the camber shall be shaped in the fresh concrete to lines and levels
detailed in the Drawings, using an appropriate tamping template.
Concrete shall not be mixed or poured when ambient shade temperatures are less than 4ºC or more
than 38ºC.
“Starter” and “end” anchor beams shall be provided for the thin concrete pavement at the
commencement and end of the paving, and changes in horizontal and vertical alignment and/or in

accordance with the Drawings or as directed by the Engineer The mesh must be folded down into the
beams.
Transverse grooves shall be etched in the fresh concrete surface utilising an appropriate rake.
Formwork shall be removed as soon as the concrete has set sufficiently so as not to cause spalling of
the concrete. Before proceeding with casting the concrete for the next shift, the surface (face) of the
joint must be cleaned, lightly roughened and treated with cement slurry.
(d) Construction Joints

Construction joints shall only be used to provide a clear, neat joint at the end of a day’s work or where
placing of the concrete is interrupted due to weather or unforeseen problems. As the mesh reinforcing
is to be laid continuously, special attention must be given to the construction joints to ensure that a
neat joint is formed while accommodating the mesh.
Concrete shall be constructed at full carriageway width. In some circumstances (e.g. to allow traffic
flow in difficult terrain) construction of half-width concrete may be permitted, but only with the
agreement of the Engineer. Where the concrete is cast in half widths a longitudinal joint shall be
formed along the centreline of the road or between adjacent longitudinal sections and along the kerb,
by casting the second pour against the first, sawing and sealing with a cold poured bitumen rubber
sealant.
The construction joints and longitudinal joint shall be sawn 10 mm wide to a depth of 13mm and
sealed with a bitumen rubber compound of the class C-R1 in Table 6602/1.
(e) Longitudinal Joints

A longitudinal joint shall be formed between the concrete pavement and the kerb; and between
adjacent longitudinal sections; by casting the second member against the first, sawing and sealing
with a cold-applied polymer modified bitumen emulsion for treating the sawn edges and a bitumen
rubber sealant (CC-E1 or C-R1) as specified in Table 6602/1.
(f) Curing
The concrete shall be cured by spreading sand or sacking over the surface of the pavement and
repeatedly wetting the materials for a period of at least seven (7) days. The Engineer may direct a
longer curing period depending on local circumstances. No traffic shall be allowed on the pavement
until a period of fourteen (14) days has elapsed.
7205 Laboratory and Site Testing
(a) General
The Contractor shall exercise control over quality of the materials incorporated and works performed
are the minimum. The Engineer may instruct additional tests at more frequent intervals where quality
of a material or work is in doubt.

Table 7205/1: Frequency of Laboratory Testing
Type of Test Frequency of Test

Aggregate properties One set per 1km (or where the material characteristics change)
One set of 3 cubes to be crushed at 7 days and one set of 3 cubes to
Concrete cube be crushed at 28 days:
strength Per mix design per materials source.
Per 1km of pavement
(b) Site Control

Visual inspections will be made to check compliance with the Drawings and Particular Specifications
for:
 Formwork;
 Reinforcement;
 Aggregate;
 Water;
 Concrete placing and finish.
A Slump Test will be carried out on every concrete batching shift, or as directed by the Engineer. The
slump shall be 40 – 60 mm. Concrete outside these limits will be rejected.
sections of the pavement by the Engineer prior to acceptance of the Works. The criteria for
acceptance are defined in Table 7205/2.

Pavement width By tape every 10 slabs ± 10mm
Pavement By tape from inspection pit in shoulder –
± 5mm
thickness every 10 slabs
Measure with straight edge and bubble – Within 2% of
Crossfall
every 10 slabs specification
Surface
3 m Straight edge – every 10 slabs 6 mm
roughness
Level between
Measure – every 20 joints 3 mm
slabs
Joint quality Visual assessment Visual acceptance
Joint width By tape – every 10 joints 3 mm

The tendered rate shall include the general requirements of Division 0000.
Item 72.01 50mm Ultra-Thin Reinforced Concrete Pavement (type of welded mesh fabric
indicated) ..................................................................................... square metre (m²)
The unit of measurement shall be the square metre of constructed UTRC. The quantity for which
payment shall be made shall be the product of the instructed average width and the measured length
The tendered rate shall include full compensation for furnishing all materials, trial mixes; protection
and transport of the mixed material; removal of dust and deleterious materials form the surface;
rectifying of any defects or damage; rectifying any high or low spots; demarcating the work area;
placing and fixing the side-forms and construction joint formers; mixing and placing the concrete;

placing, fixing and splicing the welded mesh fabric; screeding, finishing, texturing and curing; and all
other incidental s necessary to complete the work as specified, including all quality control testing.
Item 72.02 Anchor Beams .................................................................................... number (No)

The unit of measurement for the complete anchor beam in accordance with the Drawings shall be the
number.
The tendered rate shall include full compensation for furnishing all materials; excavations; mixing and
placing the concrete; bending the steel; and all other incidentals necessary to complete the work as
specified.
Item 72.03 Sawing and Sealing of Joints ........................................................ linear metre (m)
The unit of measurement for the completed sawn and sealed joint in accordance with the Drawings
and the Specifications shall be the metre.
The tender rate shall include full compensation for furnishing all equipment for sawing the joint;
furnishing all equipment and materials for sealing the joints; cleaning and treating the joint; mixing and
placing the joint sealant; and all other incidentals necessary to complete the work as specified.

Division 7300 Non-Reinforced Concrete Pavement (NRC)
7301 Scope
This Division covers all work in connection with the construction of non-reinforced Portland cement
concrete slabs, together with the associated load transferring dowels and joint sealing materials, laid
to lines, levels and dimensions, as shown on the Drawings and as directed by the Engineer.
7302 Materials
(a) Cement
Cement used for concrete shall be Portland cement as specified in Sub-clause 7102(a).
Cement may be delivered in bags or in bulk.
(b) Concrete
Concrete shall and have a minimum 28-day compressive strength as indicated in the design
requirement with a guidance mix water:cement ratio of 0.45 and minimum compressive strength of
20 MPa. Concrete mix proportions shall be calculated to suit the available materials in order to meet
the required compressive strength and slump requirements The use of low water-cement ratios (e.g.
<0.45), higher cement contents, plasticiser and high early-strength cement is beneficial in minimising
the risk of cracks.
(c) Concrete Aggregate

Concrete aggregates shall conform to the requirements of sub-clause 7202(c) for fine and coarse
aggregate except that the nominal size of the coarse aggregate shall not exceed 37.5 mm and its
gradation of comply with Table 7302/1:
Table 7302/1: Gradation for Coarse Aggregate
Standard Sieve (mm) % Passing

37.5-19mm 37.5-4.75mm
50 100 100
37.5 90-100 90-100
25 20-55
19 0-15 35-70
9.5 0-5 10-30
4.75 0-5
(d) Load Transfer Dowels

Load transfer dowels shall be provided at each joint between slabs as specified in sub-clause 7102(g).
They shall be made with 14 mm diameter mild steel reinforcing bars, 500 mm in length.
(e) Water
other substances injurious to the finished product. Water will be tested in accordance with, and shall
meet the requirements of, AASHTO T 26.
Water known to be of potable quality may be used without testing.

The following equipment, apparatus and special hand-tools shall be used:

 Concrete mixer of at least 250 litre capacity;
 Batching boxes or weighing apparatus;
 Wheelbarrows;
 Vibrating poker powered by electricity or portable generator;
 Tamping screed;
 Portable sun protection canopy if casting in direct sunlight if ambient shade temperatures are
above 25ºC;
 Grooving rake.
(a) Slabs
NRC pavement shall be constructed on a previously prepared sub-base layer that has been accepted
by the Engineer. An impervious plastic membrane shall be placed on top of the prepared sub-base
layer prior to concrete placement.
Concrete slabs shall normally be constructed at full carriageway width. In some circumstances (eg to
allow traffic flow in difficult terrain) construction of half-width concrete slabs may be permitted, but only
with the agreement of the Engineer. Longitudinal joints shall have a load transferring dowel and
sealing arrangement similar to that of transverse contraction joints. In very low volume roads it may be
permissible to use bevelled formwork to produce a “tongue in groove” load transferring arrangement
for longitudinal joints in place of dowels if approved by the Engineer.
(b) Joints
Partial depth contraction joints of 10 mm width shall be provided at 5 metre intervals in the pavement,
to relieve tensile stresses. Full depth expansion joints of 10 mm width shall be provided between slabs
at 250 metre intervals. All joints shall be filled and sealed with a mixture of sand and bitumen, with a
reservoir of bitumen provided at the top of each joint. All joints are to be provided with load transfer
steel dowels.
The dowels shall comprise 14 mm diameter mild steel reinforcing bars of 500 mm length placed at
250 mm centres at all expansion and contraction joints.
At expansion joints the dowel bar should be anchored into the concrete at one end and the other end
coated with bitumen and fitted into a PVC sleeve. The PVC sleeve shall be omitted at contraction
joints.
(c) Concrete
All concrete shall be mixed on site in small capacity batch mixers complying with the appropriate
Ethiopian Standards. Mixers with a capacity less than one bag of cement shall not be used and no
mixer shall be charged in excess of its rated capacity. Cement shall be fresh and stored in a clean dry
location. Aggregates shall be stored separately in a clean area. Proportions of aggregates shall be
measured using weighing apparatus or batching boxes. Water proportions shall be determined using
containers of known volume.
All formwork shall be well secured and free from defects or gaps, and able to resist the tamping forces.
The top edge of the formwork shall be within ± 2mm of the required finished road levels. Prior to
placing the concrete, all formwork shall be thoroughly inspected and passed by the Engineer. All wood
chips, dust, sand, construction debris and any other deleterious material shall be removed from the

formwork and base layer prior to placing the concrete. All formwork shall be wetted to ensure it is
damp when the concrete is poured. Care shall be taken during this operation such that pools of
excess water do not form at the base of the formwork.
Once the concrete had been placed uniformly within the forms, compaction shall be carried out using a
mechanical poker vibrator. Care should be taken to ensure a good bond between layers of fresh
concrete placed separately by vibrating the two layers together until a satisfactorily homogenous cross
section is obtained. No concrete shall be compacted after initial setting has commenced.
All concrete shall be compacted until no air bubbles appear on the surface of the fresh concrete. Care
shall be taken not to touch the formwork with the vibrator since this would result in concrete having
begun initial setting being exposed to re-vibration.
After placement and compaction, the camber shall be shaped in the fresh concrete to lines and levels
detailed in the Drawings, using an appropriate tamping template. In order to improve the skid-
resistance of the surface and to shorten the vehicles' breaking distance, transverse grooves shall be
etched in the fresh concrete surface utilising an appropriate rake.
Concrete shall not be mixed or poured when ambient shade temperatures are less than 4ºC or more
than 38ºC. Construction of each pavement slab shall be completed within two (2) hours of the
placement of the first concrete in the slab.
The concrete shall be cured by spreading sand or sacking over the surface of the pavement and
repeatedly wetting the materials for a period of at least seven (7) days. The Engineer may direct a
longer curing period depending on local circumstances. No traffic shall be allowed on the pavement
until a period of fourteen (14) days has elapsed.
7305 Laboratory and Site Testing
(a) General
The Contractor shall exercise control over quality of the materials incorporated and works performed
are the minimum. The Engineer may instruct additional tests conducted at more frequent intervals.
Table 7305/1: Frequency of Laboratory Testing
Type of Test Frequency of Test

Aggregate properties One set per 1km (and where the material characteristics change)
Concrete cube One set of 3 cubes to be crushed at 7 days and one set of 3 cubes to be
strength crushed at 28 days:
Per mix design per materials source.
Per 1km of pavement
(b) Site Testing

Visual inspections will be made to check compliance with the Drawings and specifications:
 Dowels
 Formwork
 Aggregate
 Water
 Concrete placing and finish

A Slump Test shall be carried out on every concrete batching shift, or as directed by the Engineer. The
slump shall be between the limits 40 – 60 mm.
sections of the NRC pavement by the Engineer prior to acceptance of the Works. The criteria for
acceptance are defined in Table 7305/2:

Slab width By tape every 10 slabs ± 10mm
Slab length By tape every 10 slabs ± 10mm
Slab thickness By tape from inspection pit in shoulder – ± 5mm
every 10 slabs
Crossfall Measure with straight edge and bubble – Within 2% of
every 10 slabs specification
Surface roughness 3 m Straight edge – every 10 slabs 6 mm
Level between slabs Measure – every 20 joints 3 mm
Joint quality Visual assessment – every 10 slabs Visual acceptance
Joint width By tape – every 10 joints 3 mm

The tendered rate shall include the general requirements of Division 0000.
Item 73.01 Non Reinforced Concrete Pavement (at specified slab thickness)
(b) Manual construction ................................................................................. square metre (m²)
The unit of measurement shall be square metres (m²) of constructed non-reinforced concrete. The
quantity for which payment shall be made shall be the product of the instructed average width and the
measured length along the centreline of the road.
 Trial mixes;
 Drilling the holes in the existing concrete,
 Placing and fixing the bars with epoxy, and
 Treating the sliding ends of the dowels.
Item 73.02 Joints

(a) Expansion joints complete (excluding dowels) ............................................ linear metre (m)
(b) Longitudinal joints: Sealed (type indicated with reference to Drawings) .... linear metre (m)
(c) Longitudinal joints: Unsealed (type indicated with reference to Drawings) linear metre (m)
(d) Sealed transverse contraction joints sawn in two separate operations (widths as shown on the
Drawings). .................................................................................................... linear metre (m)
(e) Dowel bars (mild steel) (diameter and length indicated) .................................. number (No)
(f) Tie-bars (diameter and length indicated) ......................................................... number (No)
(g) End caps for dowels at expansion joints .......................................................... number (No)
(h) Forming and sealing the joints between asphalt and concrete pavements. linear metre (m)
(i) Cleaning of tie-bars and dowels in existing concrete pavement and straightening tie-bars in
existing concrete pavement in rehabilitation work ............................................ number (No)
The unit of measurement for joints in the pavement shall be the metre of completed joint, except that
dowel bars and tie-bars across joints shall be measured separately by the numbers of each type
installed.
The tendered rate for expansion joints shall include the following specific requirements:
 Forming the joint;

 Joint filler, rounding or chamfering the corners;
 Installing a compression seal.
The tendered rate for longitudinal joints shall include the following specific requirements:
 Sawing the joint (if required);

 Inserting the seal (if required).
The tendered rate for transverse contraction joints shall include the following specific requirements:
 Sawing the joint and installing the specified type of seal;

 Appurtenant materials;
 Temporarily sealing the joint with paper rope.
The tendered rate for dowel bars and tie-bars shall include the following specific requirements:
 Supplying, cutting, placing, holding the bars in position;

 Supporting framework or cradles;
 Fixing the end caps and bond breaking materials to dowels.
The tendered rate for forming and sealing the joints between asphalt and concrete pavements shall
include the following specific requirements:
 Supplying all the necessary plant and materials;

 Forming a joint;
 Cleaning and sealing.
Item 73.03 Drilling and testing of cores

(c) 100 mm cores drilled from the pavement ......................................................... number (No)
(d) 150 mm cores drilled from the pavement for compressive strength ................ number (No)

The unit of measurement shall be the number of cores drilled or drilled and tested on the instruction of
the Engineer. Cores drilled by the Contractor at his own initiative as part of his process control or for
testing cracks sealed at the Contractor's own cost, will not be measured for payment.
 Drilling the test cores;

 Tests at an approved laboratory and other incidentals;
 Restoring the concrete pavement where holes were drilled.

Series 8000: Structures

(Including Slab and Box Culverts)
TABLE OF CONTENTS
DIVISION 8100: FOUNDATIONS FOR STRUCTURES .................................................................................. 525
8101 Scope ........................................................................................................................................ 525
8102 Materials.................................................................................................................................... 525
(a) General ..........................................................................................................................................525
(b) Rock (for rock fill) ........................................................................................................................ 525
(c) Crushed stone ................................................................................................................................ 525
(d) Granular fill ...................................................................................................................................525
(e) Sand fill .........................................................................................................................................526
(f) Structural steel ............................................................................................................................... 526
(g) Permanent Pile Casings .................................................................................................................526
(h) Driven Pile Casings ....................................................................................................................... 526
(i) Sheet Piles .....................................................................................................................................526
(j) Grouting ........................................................................................................................................526
(k) Concrete ........................................................................................................................................526
8103 General ..................................................................................................................................... 527
(a) Subsurface Data............................................................................................................................. 527
(b) Channel preservation ..................................................................................................................... 527
8104 Cofferdams, Artificial Islands and Dewatering .......................................................................... 527
(a) General ..........................................................................................................................................527
(b) Access ...........................................................................................................................................527
(c) Dewatering ....................................................................................................................................527
8105 Excavation Works ..................................................................................................................... 528
(a) General ..........................................................................................................................................528
(b) Ground surface for excavation ......................................................................................................528
(c) Excavation .....................................................................................................................................528
(d) Classification of excavated material .............................................................................................. 529
(i) Hard material ............................................................................................................................................ 529
(ii) Soft material .............................................................................................................................................. 529

(e) Blasting ......................................................................................................................................... 529
(f) Deterioration of foundation excavations ....................................................................................... 529
(g) Excavation safety .......................................................................................................................... 529
(h) Inspection ...................................................................................................................................... 530
(i) Excavation by hand ....................................................................................................................... 530
(j) Trench Method Excavation for Box/Slab Culverts ....................................................................... 530
(i) Depth of Excavation ................................................................................................................................. 530
(ii) Width of Excavation ................................................................................................................................. 530
8106 Foundations .............................................................................................................................. 530
8107 Utilisation of Excavated Material .............................................................................................. 531
8108 Backfill and Fill near Structures ................................................................................................ 531
(a) General .......................................................................................................................................... 531
(b) Backfill.......................................................................................................................................... 531
(c) Fill ................................................................................................................................................. 532
(d) Select Granular Backfill ................................................................................................................ 532
(e) Fill within restricted areas ............................................................................................................. 532
8109 Foundation Fill .......................................................................................................................... 532
8110 Bedding and Laying of Box/Slab Culverts ................................................................................ 533
(i) Cast in-situ Invert Slab Culverts ............................................................................................................... 533
(ii) Precast Invert Slabs................................................................................................................................... 533
(iii) Placing of Upper Portion of Culverts........................................................................................................ 533
8111 Grouting of Rock Fissures ........................................................................................................ 533
8112 Foundation Dowels ................................................................................................................... 534
8113 Foundation Lining ..................................................................................................................... 534
8114 Foundation Piling ...................................................................................................................... 534
(a) General .......................................................................................................................................... 534
(b) Piling Layout ................................................................................................................................. 534
(c) Alternative Designs for Piling and Piling Layouts ........................................................................ 534
(i) Submission................................................................................................................................................ 534
(ii) Design ....................................................................................................................................................... 535
(iii) Basis of payment ...................................................................................................................................... 535
(d) Details to be furnished by the Contractor ...................................................................................... 536
(e) Pile-installation Frames and Equipment ....................................................................................... 537
(f) Piling Platforms ............................................................................................................................ 537
(g) Setting Out .................................................................................................................................... 537

(h) Ground Surface of Foundation Piling............................................................................................ 537
(i) Cast in-situ concrete piles..............................................................................................................537
(i) Reinforcement ........................................................................................................................................... 537
(ii) Concreting of Piles .................................................................................................................................... 538
(j) Precast Concrete Piles ...................................................................................................................539
(i) Manufacture .............................................................................................................................................. 539
(ii) Handing, Transport and Storage ................................................................................................................ 539
(iii) Lengthening of Precast Piles ..................................................................................................................... 539
(k) Steel Piles ......................................................................................................................................539
(l) Driving Piles..................................................................................................................................540
(i) Pile-installation frames ............................................................................................................................. 540
(ii) Water Jetting ............................................................................................................................................. 540
(iii) Installation Sequence ................................................................................................................................ 540
(iv) Heaving of Piles ........................................................................................................................................ 540
(v) Bulbous Bases ........................................................................................................................................... 541
(vi) Piling Alignment ....................................................................................................................................... 541
(m) Augering and Boring ..................................................................................................................... 541
(i) Auger and Bore Pile Holes........................................................................................................................ 541
(ii) Under-reaming .......................................................................................................................................... 541
(iii) Bulbous Bases ........................................................................................................................................... 541
(iv) Hole Inspections........................................................................................................................................ 541
(n) Rock Sockets .................................................................................................................................542
(o) Obstructions ..................................................................................................................................542
(i) Identified Obstructions .............................................................................................................................. 542
(ii) Unidentified Obstructions ......................................................................................................................... 542
(iii) Classification of Materials ........................................................................................................................ 542
(p) Driven Displacement and Prefabricated Piles ...............................................................................542
(q) Determining Pile Lengths ..............................................................................................................543
(r) Piling Data .....................................................................................................................................543
(s) Stripping the Pile Heads ................................................................................................................543
(t) Construction of Pile-capping Slab .................................................................................................544
(u) Core Drilling .................................................................................................................................544
(v) Load Test .......................................................................................................................................544
(i) General ...................................................................................................................................................... 544

(ii) Loading ..................................................................................................................................................... 545
(iii) Ultimate Test Load.................................................................................................................................... 545
(w) Defective Piles .............................................................................................................................. 545
(x) Standing Time in Respect of Piles-installation Frames ................................................................. 545
8115 Caissons ................................................................................................................................... 546
(a) General .......................................................................................................................................... 546
(b) Construction and sinking .............................................................................................................. 546
(c) Founding ....................................................................................................................................... 547
(d) Data ............................................................................................................................................... 547
(e) Filling the caissons ........................................................................................................................ 547
(i) Concrete seal............................................................................................................................................. 547
(ii) Filling ....................................................................................................................................................... 548
(iii) Stripping ................................................................................................................................................... 548
(iv) Concrete screed below the caisson cover slabs ......................................................................................... 548
DIVISION 8200 FALSEWORK, FORMWORK, AND CONCRETE FINISHES ..................................................... 560
8201 Scope ........................................................................................................................................ 560
8202 Dimensions ............................................................................................................................... 560
8203 Material Requirements for Falsework and Formwork ............................................................... 560
(a) Falsework ...................................................................................................................................... 560
(b) Formwork...................................................................................................................................... 560
(i) Tongue-and-groove boarding .................................................................................................................... 561
(ii) Steel forms to exposed surfaces ................................................................................................................ 561
(iii) Void formers ............................................................................................................................................. 561
(iv) Chamfer and recess fillets ......................................................................................................................... 561
(v) Jack rods for sliding formwork ................................................................................................................. 561
8204 Design and Construction Requirements ................................................................................... 562
(a) Drawings ....................................................................................................................................... 562
(b) Design ........................................................................................................................................... 563
(i) General ..................................................................................................................................................... 563
(ii) Falsework.................................................................................................................................................. 563
(iii) Formwork ................................................................................................................................................. 563
(iv) Sliding formwork ...................................................................................................................................... 563
(c) Construction .................................................................................................................................. 564
(i) General ..................................................................................................................................................... 564

(ii) Falsework .................................................................................................................................................. 564
(iii) Formwork.................................................................................................................................................. 564
(iv) Formwork to exposed surfaces.................................................................................................................. 565
(v) Formwork for open joints ......................................................................................................................... 565
(vi) Openings and wall chases ......................................................................................................................... 566
(vii) Sliding formwork ........................................................................................................................... 566
(viii) Permanent formwork ...................................................................................................................... 568
(ix) Preparing the formwork ............................................................................................................................ 568
(d) Removal of forms and falsework ..................................................................................................568
8205 Formed Surfaces: Classes of Finish ......................................................................................... 569
(a) General ..........................................................................................................................................569
(b) Class F1 surface finish ..................................................................................................................569
(c) Class F2 surface finish ..................................................................................................................569
(d) Class F3 surface finish ..................................................................................................................570
(e) Board surface finish ...................................................................................................................... 570
(f) Protecting the surfaces ..................................................................................................................570
8206 Remedial Treatment of Formed Surfaces ................................................................................. 570
(a) General ..........................................................................................................................................570
(b) Repairs to surface defects ..............................................................................................................570
(c) Rubbing the surfaces ..................................................................................................................... 571
8207 Unformed Surfaces: Classes of Finish ..................................................................................... 571
(a) Class U1 surface finish (rough) .....................................................................................................571
(b) Class U2 surface finish (floated) ...................................................................................................571
(c) Class U3 surface finish (smoothly finished) .................................................................................571
DIVISION 8300: STEEL REINFORCEMENT FOR STRUCTURES ................................................................... 574
8301 Scope ........................................................................................................................................ 574
8302 Materials Requirement .............................................................................................................. 574
(a) Steel reinforcement ....................................................................................................................... 574
(b) Mass of Reinforcing Bars ..............................................................................................................574
(c) Mechanical couplers ...................................................................................................................... 574
(d) Supply and Storage of Materials ...................................................................................................574
(a) Equipment .....................................................................................................................................575

(b) Bending of Reinforcement ............................................................................................................ 575
(c) Surface Conditions ........................................................................................................................ 575
(d) Placing and Fixing ........................................................................................................................ 575
(e) Cover ............................................................................................................................................. 576
(f) Laps and Joints .............................................................................................................................. 577
(g) Welding ......................................................................................................................................... 577
DIVISION 8400: CONCRETE FOR STRUCTURES ....................................................................................... 579
8401 Scope ........................................................................................................................................ 579
8402 Materials ................................................................................................................................... 579
(a) Cement .......................................................................................................................................... 579
(b) Admixtures.................................................................................................................................... 579
(i) Air-Entraining Admixtures ....................................................................................................................... 579
(ii) Type A Water-Reducing Admixtures ........................................................................................................ 579
(iii) Type B Retarding Admixtures .................................................................................................................. 579
(iv) Type C Accelerating Admixtures .............................................................................................................. 579
(v) Type D Water-Reducing and Retarding Admixtures ................................................................................. 579
(vi) Type E Water-Reducing and Accelerating Admixtures ............................................................................. 579
(vii) Type F Water-Reducing, High Range Admixtures ......................................................................... 579
(viii) Type G Water-Reducing, High Range, and Retarding Admixtures ................................................ 579
(c) Aggregates .................................................................................................................................... 579
(i) Fine Aggregate for Portland Cement Concrete. ........................................................................................ 580
(ii) Coarse Aggregate for Portland Cement Concrete. .................................................................................... 581
(d) Water ............................................................................................................................................. 581
8403 Storage of Materials ................................................................................................................. 581
(a) Cement .......................................................................................................................................... 581
(b) Aggregates .................................................................................................................................... 582
(c) Storage Capacity ........................................................................................................................... 582
(d) Deteriorated Material .................................................................................................................... 583
8404 Concrete for Structures ............................................................................................................ 583
(a) Concrete Grade and Class ............................................................................................................. 583
(b) Minimum Cement Content ............................................................................................................ 583
(c) Maximum Water/Cement Ratio .................................................................................................... 583
(d) Maximum Cement Content ........................................................................................................... 583
(e) Design of Concrete Mixes for Structures ...................................................................................... 583

(f) Prescribed Mix .............................................................................................................................. 584
(a) Storage and Handling of Material .................................................................................................584
(b) Measuring Material ....................................................................................................................... 585
(i) Cement ...................................................................................................................................................... 585
(ii) Water ......................................................................................................................................................... 585
(iii) Aggregates ................................................................................................................................................ 585
(iv) Admixtures................................................................................................................................................ 585
(v) Adjustment to Mix Proportions ................................................................................................................. 585
(c) Batching Plant, Mixers, and Agitators ........................................................................................... 585
(d) Mixing ...........................................................................................................................................586
(i) Central-Mix Plant...................................................................................................................................... 586
(ii) Truck Mixer .............................................................................................................................................. 586
(e) Delivery .........................................................................................................................................586
(i) Truck mixer/agitator.................................................................................................................................. 587
(ii) Non-Agitating Equipment ......................................................................................................................... 587
(f) Batching and Mixing ..................................................................................................................... 587
(i) General ...................................................................................................................................................... 587
(ii) Charging the Mixer ................................................................................................................................... 587
(iii) Mixing and Discharge ............................................................................................................................... 588
(iv) Maintenance and Cleaning of the Mixer ................................................................................................... 588
(v) Standby Mixer ........................................................................................................................................... 588
(vi) Ready Mixed Concrete.............................................................................................................................. 588
(g) Trial Mixes ....................................................................................................................................588
(h) Compressive Strength ...................................................................................................................589
(i) Consistency and Workability .........................................................................................................589
(j) Temperature and Weather Conditions ........................................................................................... 590
(i) General ...................................................................................................................................................... 590
(ii) Cold Weather ............................................................................................................................................. 590
(iii) Hot Weather .............................................................................................................................................. 591
8406 Handling, Placing and Compaction of Concrete ....................................................................... 591
(a) General ..........................................................................................................................................591
(b) Placing ...........................................................................................................................................592
(i) General ...................................................................................................................................................... 592

(ii) Sequence of Placement for Substructures ................................................................................................. 592
(iii) Vertical members ...................................................................................................................................... 593
(iv) Superstructures ......................................................................................................................................... 593
(v) Arches ....................................................................................................................................................... 593
(vi) Box/Slab culverts ...................................................................................................................................... 593
(vii) Precast elements ............................................................................................................................. 593
(viii) Placing underwater ......................................................................................................................... 593
(ix) Tremies ..................................................................................................................................................... 593
(x) Concrete pumps ........................................................................................................................................ 594
(xi) Placing Methods ....................................................................................................................................... 594
(xii) Compaction .................................................................................................................................... 595
8407 Construction Joints ................................................................................................................... 596
(a) General .......................................................................................................................................... 596
(b) Preparation of Surfaces ................................................................................................................. 596
(c) Placing Fresh Concrete at Construction Joints .............................................................................. 596
(d) Bonding ......................................................................................................................................... 597
(e) Bonding and Doweling to Existing Structures .............................................................................. 597
8408 Expansion and Contraction Joints ............................................................................................ 597
(a) Open joints .................................................................................................................................... 597
(b) Filled joints ................................................................................................................................... 597
(c) Steel joints..................................................................................................................................... 598
(d) Water stops .................................................................................................................................... 598
(e) Compression joint seals ................................................................................................................ 598
(f) Elastomeric expansion joint seal ................................................................................................... 598
8409 Finishing Plastic Concrete ........................................................................................................ 598
(a) General .......................................................................................................................................... 598
(b) Striking of Formwork ................................................................................................................... 598
8410 Curing Concrete........................................................................................................................ 599
(a) General .......................................................................................................................................... 599
(b) Forms in-place method.................................................................................................................. 599
(c) Water method ................................................................................................................................ 599
(d) Liquid membrane curing compound method ................................................................................ 600
(e) Steam curing (precast units) .......................................................................................................... 600
(f) Curing concrete with sliding formwork ........................................................................................ 600
8411 Pipes and Conduits .................................................................................................................. 601

8412 Precast Concrete ...................................................................................................................... 601
DIVISION 8500: TIMBER STRUCTURES ................................................................................................... 604
8501 Scope ........................................................................................................................................ 604
8502 Material for Timber Structures .................................................................................................. 604
(a) Untreated Structural Timber and Lumber ...................................................................................... 604
(b) Treated Structural Timber and Lumber ......................................................................................... 604
(c) Hardware .......................................................................................................................................604
(d) Yard lumber ...................................................................................................................................604
(e) Structural Shapes, Rods, and plates ............................................................................................... 604
(f) Paint ..............................................................................................................................................604
(g) Preservative Treatment of Timber .................................................................................................605
(i) Description ................................................................................................................................................ 605
(ii) Treating Plant Equipment ......................................................................................................................... 605
(iii) Preservatives ............................................................................................................................................. 605
(a) General ..........................................................................................................................................605
(b) Storage of Materials ...................................................................................................................... 606
(c) Treated Timber .............................................................................................................................. 606
(d) Untreated Timber........................................................................................................................... 606
(e) Holes for Bolts, Dowels, Rods, and Lag Screws ...........................................................................606
(f) Bolts and Washers ......................................................................................................................... 607
(g) Countersinking .............................................................................................................................. 607
(h) Framing .........................................................................................................................................607
(i) Framed Bents ................................................................................................................................ 607
(j) Caps for all Bents .......................................................................................................................... 607
(k) Bracing ..........................................................................................................................................607
(l) Stringers ........................................................................................................................................608
(m) Plank Floors or Decks ...................................................................................................................608
(n) Transversely Nail-Laminated Decks ............................................................................................. 608
(o) Wheel Guards and Railings ...........................................................................................................609
(p) Trusses ...........................................................................................................................................609
(q) Drains ............................................................................................................................................609
(r) Painting .........................................................................................................................................609

(s) Acceptance .................................................................................................................................... 609
DIVISION 8600: PRE-STRESSING ............................................................................................................611
8601 Scope .........................................................................................................................................611
8602 Materials ....................................................................................................................................611
(a) General .......................................................................................................................................... 611
(b) Pre-stressing steel .......................................................................................................................... 611
(i) General ..................................................................................................................................................... 611
(ii) Bars ........................................................................................................................................................... 611
(iii) Wires and seven-wire steel strand ............................................................................................................. 611
(iv) Straightness ............................................................................................................................................... 611
(v) Surface condition ...................................................................................................................................... 611
(vi) Cutting of Pre-stressing Tendons .............................................................................................................. 612
(vii) Galvanising .................................................................................................................................... 612
(viii) Welds.............................................................................................................................................. 612
(c) Anchorage-s and couplers ............................................................................................................. 612
(d) Ducts ............................................................................................................................................. 612
(e) Cable supports ............................................................................................................................... 613
(f) Positioning of Tendons and Ducts for Pre-stressing Tendons ....................................................... 613
(g) Tendon spacers .............................................................................................................................. 613
(h) Grout ............................................................................................................................................. 613
(i) Materials ................................................................................................................................................... 613
(ii) Properties of the grout .............................................................................................................................. 614
(i) Protecting agents for un-bonded tendons ...................................................................................... 614
(j) Testing ........................................................................................................................................... 615
(a) Equipment ..................................................................................................................................... 615
(i) General ..................................................................................................................................................... 615
(ii) Tensioning and measuring equipment....................................................................................................... 615
(iii) Grouting equipment .................................................................................................................................. 615
(b) Technical Data .............................................................................................................................. 616
(i) Tendon alignment ..................................................................................................................................... 616
(ii) Tendon system .......................................................................................................................................... 616
(iii) Tensioning the tendons ............................................................................................................................. 616
(iv) Tensioning force ....................................................................................................................................... 616

(v) Extension .................................................................................................................................................. 616
(vi) Pre-stressing losses in tendons .................................................................................................................. 616
(vii) Anchorages ..................................................................................................................................... 617
(viii) Bursting reinforcement ................................................................................................................... 617
(ix) Pre-camber ................................................................................................................................................ 617
(x) Compressive strength of the concrete during transfer ............................................................................... 617
(c) Pre-stressing System ..................................................................................................................... 617
(d) Drawings Prepared by the Contractor ........................................................................................... 617
(e) Pre-casting .....................................................................................................................................618
(i) Casting yard on the site ............................................................................................................................. 618
(ii) Manufacture off the site ............................................................................................................................ 618
(iii) Manufacture .............................................................................................................................................. 618
(f) Pre-Tensioning .............................................................................................................................. 619
(g) Post-Tensioning ............................................................................................................................. 619
(i) Storage, handling and protection............................................................................................................... 619
(ii) Fabrication ................................................................................................................................................ 620
(iii) Installation ................................................................................................................................................ 620
(iv) Concrete strength ...................................................................................................................................... 621
(v) Tensioning ................................................................................................................................................. 621
(vi) Permanent Protection and bonding of tendons .......................................................................................... 623
8604 Loss of Pre-stress ..................................................................................................................... 625
DIVISION 8700 BRIDGE BEARINGS, PARAPETS, RAILINGS, FOOTWAYS, NO-FINES CONCRETE, WATER-
PROOFING AND DRAINAGE FOR STRUCTURES ......................................................................................... 627
8701 Scope ........................................................................................................................................ 627
8702 Bridge Bearings ........................................................................................................................ 627
(a) Material .........................................................................................................................................627
(i) General ...................................................................................................................................................... 627
(ii) Roofing Felt .............................................................................................................................................. 627
(iii) Elastomer .................................................................................................................................................. 627
(iv) Sliding Surface using PTFE ...................................................................................................................... 627
(v) Stainless steel plate ................................................................................................................................... 627
(vi) Stainless steel dowels and bolts ................................................................................................................ 627
(vii) Steel plate ....................................................................................................................................... 628

(viii) Mortar ............................................................................................................................................ 628
(b) Concrete Hinges ............................................................................................................................ 628
(c) Roofing Felt .................................................................................................................................. 628
(d) Elastomeric Bearings .................................................................................................................... 629
(i) Technical data ........................................................................................................................................... 629
(ii) Alternative bearings .................................................................................................................................. 629
(iii) Inspection and testing ............................................................................................................................... 629
(e) Proprietary Bearings ..................................................................................................................... 630
(i) General ..................................................................................................................................................... 630
(ii) Drawings and approval ............................................................................................................................. 630
(iii) Technical data ........................................................................................................................................... 630
(iv) Design ....................................................................................................................................................... 630
(v) Construction.............................................................................................................................................. 631
(vi) Inspection and testing ............................................................................................................................... 632
(f) Dowels and Guides ....................................................................................................................... 632
(g) Storage and Handling .................................................................................................................... 632
(h) Installation .................................................................................................................................... 632
8703 Bridge Parapets, Railings and Footways .................................................................................. 633
(a) Materials ....................................................................................................................................... 633
(i) Concrete .................................................................................................................................................... 633
(ii) Structural steel .......................................................................................................................................... 633
(iii) Structural aluminium ................................................................................................................................ 633
(b) Concrete Parapets.......................................................................................................................... 633
(c) Metal Railings ............................................................................................................................... 634
(d) Bridge Number Plates ................................................................................................................... 634
(e) Concrete Footways ........................................................................................................................ 634
(f) Concrete Surface Finish Requirements ......................................................................................... 634
(g) Construction Tolerances ................................................................................................................ 634
8704 Joints in Structures ................................................................................................................... 635
(a) General .......................................................................................................................................... 635
(b) Movement joints ........................................................................................................................... 635
(i) Vertical Expansion Joints .......................................................................................................................... 635
(ii) Barrier Contraction Joints ......................................................................................................................... 635
(iii) Barrier Expansion Joints ........................................................................................................................... 635
(c) Materials ....................................................................................................................................... 635

(i) General ...................................................................................................................................................... 635
(ii) Joint filler .................................................................................................................................................. 636
(iii) Sealants ..................................................................................................................................................... 636
(iv) Preformed elastomeric compression seals ................................................................................................. 637
(v) Water stops ................................................................................................................................................ 637
(vi) Accessory materials - Primers ................................................................................................................... 637
(vii) Accessory materials - Adhesives .................................................................................................... 637
(viii) Accessory materials - Bond breakers ............................................................................................. 637
(ix) Accessory materials - Backup material ..................................................................................................... 637
(x) Accessory materials - Filled and unfilled joints ........................................................................................ 637
(xi) Accessory materials - Filled Joints ........................................................................................................... 637
(xii) Accessory materials - Unfilled joints ............................................................................................. 637
(xiii) Accessory materials - Epoxy Mortar Nosings ................................................................................ 637
(xiv) Accessory materials - Concrete Nosings ........................................................................................ 637
(d) Asphaltic plug type expansion joint systems .................................................................................638
(e) Sealing of Joints ............................................................................................................................ 638
(i) General ...................................................................................................................................................... 638
(ii) Preparation of joints .................................................................................................................................. 639
(iii) Sealants ..................................................................................................................................................... 639
(iv) Preformed compression seals .................................................................................................................... 639
(v) Water stops ................................................................................................................................................ 639
(f) Proprietary Expansion Joints .........................................................................................................639
(i) General ...................................................................................................................................................... 639
(ii) Dimensions ............................................................................................................................................... 639
(iii) Design and manufacture............................................................................................................................ 640
(g) Installation of Expansion Joints ....................................................................................................640
8705 No-Fines Concrete .................................................................................................................... 640
(a) Materials ........................................................................................................................................640
(b) Grades on No-Fines Concrete .......................................................................................................641
(c) Batching and Mixing ..................................................................................................................... 641
(d) Placing ...........................................................................................................................................641
(e) Protection ......................................................................................................................................641
8706 Drainage for Structures ............................................................................................................. 642
(a) Weep holes, drainage pipes and channeling ..................................................................................642

(b) No-fines concrete blocks ............................................................................................................... 642
(c) Synthetic-fibre filter fabric ............................................................................................................ 642
(d) Crushed stone in drainage strips behind walls .............................................................................. 642
DIVISION 8800: STRUCTURAL STEELWORK ............................................................................................ 648
8801 Scope ........................................................................................................................................ 648
8802 Materials ................................................................................................................................... 648
(a) Structural steel .............................................................................................................................. 648
(b) Bolts, nuts and washers ................................................................................................................. 648
(c) Friction-grip fasteners: .................................................................................................................. 648
(d) Welding consumables ................................................................................................................... 648
(e) Test certificates ............................................................................................................................. 648
8803 Codes of Practice ..................................................................................................................... 648
8804 Shop Details ............................................................................................................................. 648
8805 Fabrication and Assembly ........................................................................................................ 649
(a) General .......................................................................................................................................... 649
(b) Marking the steel ........................................................................................................................... 649
(c) Cutting .......................................................................................................................................... 649
(d) Holes for fasteners ........................................................................................................................ 649
(e) Joints in compression .................................................................................................................... 649
(f) Hollow sections ............................................................................................................................. 649
(g) Alignment of holes ........................................................................................................................ 649
(h) Welding ......................................................................................................................................... 649
(i) Bolting .......................................................................................................................................... 650
(j) Welded Stud Shear Connectors ..................................................................................................... 650
(k) Friction-grip fastening................................................................................................................... 650
(l) Riveting ......................................................................................................................................... 650
(m) Trimming ...................................................................................................................................... 650
(n) Corrosion prevention .................................................................................................................... 650
(i) Painting ..................................................................................................................................................... 650
(ii) Sprayed metal coatings ............................................................................................................................. 651
(iii) Galvanizing ............................................................................................................................................... 651
8806 Erection ..................................................................................................................................... 651
(a) General .......................................................................................................................................... 651
(b) Safety during erection ................................................................................................................... 651

(c) Alignment ......................................................................................................................................651
(d) Corrections ....................................................................................................................................651
(e) Grouting ........................................................................................................................................652
8807 Testing ....................................................................................................................................... 652
(a) Testing by the Engineer .................................................................................................................652
(b) Process control .............................................................................................................................. 652
DIVISION 8900: STONE M ASONRY STRUCTURES .................................................................................... 654
8901 Scope ........................................................................................................................................ 654
8902 Stone Masonry Walls ................................................................................................................ 654
(a) Plain packed stonewalls ................................................................................................................654
(b) Cement-mortared stone walls ........................................................................................................654
8903 Classes of Masonry .................................................................................................................. 654
(a) Class A ..........................................................................................................................................655
(b) Class B ..........................................................................................................................................655
(c) Dimensioned Masonry ..................................................................................................................655
8904 Material Requirements for Stone Masonry Structures .............................................................. 655
(a) Stone..............................................................................................................................................655
(i) Sizes and shapes ........................................................................................................................................ 655
(ii) Dressing .................................................................................................................................................... 655
(iii) Bed surface ............................................................................................................................................... 656
(iv) Joint surfaces ............................................................................................................................................. 656
(v) Arch-ring stone-joint surfaces ................................................................................................................... 656
(vi) Stratification .............................................................................................................................................. 656
(vii) Finish for exposed faces ................................................................................................................. 656
(b) Quarry Operations ......................................................................................................................... 657
(c) Mortar............................................................................................................................................657
(a) Excavation and backfill .................................................................................................................657
(b) Falsework ......................................................................................................................................657
(c) Selection and Placing ....................................................................................................................658
(i) Class A Masonry ....................................................................................................................................... 658
(ii) Class B Masonry ....................................................................................................................................... 658
(d) Beds and Joints .............................................................................................................................. 659

(e) Headers ......................................................................................................................................... 659
(f) Backing ......................................................................................................................................... 659
(g) Coping ........................................................................................................................................... 659
(h) Parapet walls ................................................................................................................................. 660
(i) Facing for Concrete ....................................................................................................................... 660
(i) Stone masonry constructed prior to placing concrete ............................................................................... 660
(ii) Concrete Placed before constructing masonry .......................................................................................... 660
(j) Pointing ......................................................................................................................................... 661
(k) Plastering of Masonry Walls ......................................................................................................... 661
(l) Weep Holes ................................................................................................................................... 661
(m) Cleaning Exposed Faces ............................................................................................................... 662
(n) Weather Limitations ...................................................................................................................... 662
DIVISION 81000: MECHANICALLY STABILISED EARTH ............................................................................ 664
81001 Scope ................................................................................................................................ 664
81002 Materials ............................................................................................................................ 664
(a) Concrete Panels ............................................................................................................................. 664
(b) Steel panels ................................................................................................................................... 664
(c) Welded wire mesh panels .............................................................................................................. 664
(d) Metallic soil reinforcements .......................................................................................................... 664
(e) Fasteners between the facing and reinforcing elements ................................................................ 664
(f) Polymeric soil reinforcements and joints ...................................................................................... 665
(g) Accessory proprietary products..................................................................................................... 665
(h) Fill material in MSE structures ..................................................................................................... 665
81003 Manufacturing and Handling the Cladding Panels ............................................................ 665
(a) Concrete panels ............................................................................................................................. 665
(b) Steel panels ................................................................................................................................... 665
(c) Welded wire mesh panels .............................................................................................................. 665
(d) Accessories ................................................................................................................................... 665
81004 Construction ...................................................................................................................... 665
(a) Foundation .................................................................................................................................... 665
(b) Construction of the MSE structure ................................................................................................ 666
(c) Fabricating and construction tolerances: ....................................................................................... 666
81005 Quality Assurance ............................................................................................................. 666
(a) General .......................................................................................................................................... 666

(b) Cladding panels ............................................................................................................................. 667
(c) Soil reinforcement ......................................................................................................................... 667
(d) Fill in MSE ....................................................................................................................................667
(e) Materials and components not covered in the specifications ........................................................ 667
81006 Design Check .................................................................................................................... 667
81007 Measurement and Payment .............................................................................................. 667
DIVISION 81100: CONSTRUCTION TOLERANCES FOR STRUCTURES ......................................................... 669
81101 Scope ................................................................................................................................ 669
81102 Definitions .......................................................................................................................... 669
(a) Position..........................................................................................................................................669
(b) Alignment ......................................................................................................................................669
(c) Leading and Cross Sectional Dimensions ..................................................................................... 669
(d) Levels ............................................................................................................................................669
(e) Surface Regularity ......................................................................................................................... 669
81103 Tolerances ......................................................................................................................... 669
(a) Foundations ...................................................................................................................................670
(b) Precast Beams ............................................................................................................................... 671
(c) Precast Beams and Panels .............................................................................................................672
(d) Precast Pre-stressed Concrete Structural Elements .......................................................................672
(e) Reinforcing Steel ........................................................................................................................... 673
(i) Tension Steel ............................................................................................................................................. 673
(ii) Concrete Cover ......................................................................................................................................... 673
(iii) Spacing between Bars ............................................................................................................................... 673
(iv) Bending of Reinforcement ........................................................................................................................ 673
(f) Pre-stressing ..................................................................................................................................673
(g) Bridge Bearings ............................................................................................................................. 674
(h) Concrete Pavement Slab and Segmental Block Paving .................................................................674
(i) Level and Grade ........................................................................................................................................ 674
(ii) Width of Pavement and the Position of Pavement Edges ......................................................................... 675
(iii) Joints ......................................................................................................................................................... 675
(iv) Thickness .................................................................................................................................................. 675
(v) Cross Section ............................................................................................................................................ 675
(vi) Surface Regularity .................................................................................................................................... 675
(vii) Dowels ........................................................................................................................................... 676

(viii) Joint Sealers ................................................................................................................................... 676
(ix) Sub-base ................................................................................................................................................... 676
(x) Kerbs and Inverts ...................................................................................................................................... 676
(xi) Footways and Paving ................................................................................................................................ 676
(xii) Mower Strips and Edging .............................................................................................................. 676
(i) Miscellaneous ............................................................................................................................... 676
(i) Chamfers ................................................................................................................................................... 676
(ii) Kerbs, Copings, Footways, Bridge Railings, Parapets, Guard rails, etc. .................................................. 676
(iii) Natural Stone, Precast and In-situ Concrete, and Asphalt Kerbs ............................................................. 676
(iv) Metal Beam Guardrails ............................................................................................................................. 677

LIST OF TABLES
Table 8102/1: Rock Classification ........................................................................................................ 525
Table 8108/1: Select Granular Backfill Gradation ................................................................................ 532
Table 8204/1: Minimum Form/Support Release Criteria ..................................................................... 569
Table 8302/1: Mass of Reinforcing Bars .............................................................................................. 574
Table 8303/1: Minimum concrete cover over reinforcement ................................................................ 577
Table 8402/1: Maximum amount of deleterious substances ............................................................... 580
Table 8402/2: Grading of Fine Aggregate ............................................................................................ 580
Table 8402/3: Nominal Size and Grading of Coarse Aggregate .......................................................... 581
Table 8404/1: Grade of Concrete for Structures .................................................................................. 583
Table 8406/1: Hand Held Vibratory Requirements .............................................................................. 596
Table 8409/1: Minimum Period before Striking Formwork for Concrete for Structures ....................... 599
Table 8502/1: Preservatives for Timber ............................................................................................... 605
Table 8704/1: Types of movement joints ............................................................................................. 635
Table 8705/1: Grades of No-Fines concrete ........................................................................................ 641
Table 8905/1: Bed Thicknesses for Face Stones ................................................................................ 659
Table 81103/1: Piles ............................................................................................................................. 670
Table 81103/2: Caissons: ..................................................................................................................... 670
Table 81103/3: Footings, pile caps, caisson cover slabs, etc .............................................................. 670
Table 81103/4: Columns, walls, pier, abutments, etc .......................................................................... 671
Table 81103/5: Bridge and Culvert Superstructure .............................................................................. 671
Table 81103/6: Precast Beam Tolerances ........................................................................................... 671
Table 81103/7: Members Other Than Flat Panels: .............................................................................. 672
Table 81103/8: All Units ....................................................................................................................... 672
Table 81103/9: Cross Sectional Dimensions and Straightness ........................................................... 673
Table 81103/10: Pre-stressing Tendons Tolerance .............................................................................. 673
Table 81103/11: Bridge Bearing Tolerance .......................................................................................... 674
Table 81103/12: Fabrication and Assembly Tolerances for Structural Steel........................................ 674
Table 81103/13: Allowable Deviations from Grade .............................................................................. 675
Table 81103/14: Construction Tolerances for Kerbs ............................................................................ 677

Division 8100: Foundations for Structures
8101 Scope
This Division provides specifications for the construction of foundations for structures including
bridges; retaining walls; the bedding and laying of box and slab culverts; and other special structures
ordered by the Engineer. This includes excavation and back filling; and for the construction of the
foundation itself as well as the pile cap or caisson cover slabs.
8102 Materials
(a) General
Materials used in the permanent foundation work shall comply with the requirements specified for the
particular material in series 8000 of the Specifications.
(b) Rock (for rock fill)

Stones shall be hard, angular, field or quarry stones of such quality that they will not disintegrate on
exposure to water or weathering. The stones shall be free from overburden, shale, and organic
material. Neither the breadth nor thickness of a single stone shall be less than one-third its length.
Not more than 10% of the total volume of rock fill shall consist of stones having a mass of less than
0.5 of the mass specified and not more than 10% of the total volume of rock fill shall consist of stones
having a mass more than 5 times the mass specified. Not less than 50% of the total volume of rock fill
shall consist of stones larger than the specified mass.
The rock shall be classified as shown in Table 8102/1
Table 8102/1: Rock Classification
Unconfined
Description of Hardness Compressive
Class Description
Field Indicator Tests Strength
(MPa)
Material crumbles under firm (moderate) blows with a sharp end
Very soft
R1 of geological pick and can be peeled off with a knife; it is too hard 0.7 to 3
rock
to cut a tri-axial sample by hand
Can just be scraped and peeled with a knife;
R2 Soft rock indentations 1 mm to 3 mm show in specimens with firm 3 to 10
(moderate) blows of the pick point
Cannot be scraped or peeled with a knife; handheld specimen can
R3 Hard rock be broken with hammer end of a geological pick with a single firm 10 to 20
(moderate) blow
Very hard Hand-held specimen breaks with hammer end of pick under more
R4 20 to 70
rock than one below
Extremely Specimen requires many blows with geological pick to break
R5 > 70.0
hard rock through intact material
(c) Crushed stone

Crushed stone used for the construction of crushed stone fill shall be from sound unweathered rock
(d) Granular fill

Granular fill used for the construction of compacted granular fill shall be approved granular material of
at least gravel sub-base quality.
Granular backfill required for compacting against earth-retaining structures shall consist of well-graded
crushed or natural gravel, stone, rock fill, or natural sand or a combination of any of these. It shall not
contain a soluble sulphate content exceeding 2.5 g per litre as determined in accordance with the
Not less than 95% of the material shall pass a 125 mm BS sieve and at least 90% shall pass the 75
mm BS sieve but not more than 10% shall pass the 75-micron BS sieve.
(e) Sand fill

Sand used for filling of caissons shall be clean, hard and free from lumps of clay, organic or other
deleterious matter.
(f) Structural steel

Steel in steel piles shall comply with the requirements of AASHTO M-270 for the grade of steel
specified on the Drawings.
I and H sections shall comply with the requirements of AASHTO M-160.
Fabricated sections shall comply with the details shown on the Drawings.
(g) Permanent Pile Casings

Permanent pile casings shall be sufficiently rigid so as not to deform permanently or damage during
handing and construction.
The casings shall be sufficiently dense to prevent the fluid components of the concrete from leaking
during the placing of the concrete or thereafter.
Where steel casings contribute to the strength of the pile, the casings shall have a minimum wall
thickness of 4.5 mm and shall comply with the requirements of ASTM A-252-68. Welded joints shall
comply with the requirements of Division 8800 of these specifications.
(h) Driven Pile Casings

Driven pile casings shall have sufficient strength to permit their being driven and not being distorted by
the driving of adjacent piles, and they shall be sufficiently watertight to prevent water leaking through
the casing walls during the placing of concrete.
(i) Sheet Piles

Steel sheet piles shall conform to AASHTO M-202M.
All other sheet piles shall conform to the requirements prescribed above for the particular material
specified. As far as possible, the joints shall be made watertight when the piles are in place.
(j) Grouting
Cement grout shall meet the appropriate requirements of sub-clause 8602(h) of these specifications.
Proprietary brand grout shall be prepared and used strictly in accordance with the instructions of the
manufacturer.
(k) Concrete
All concrete used for the construction of foundations of structures shall be in accordance with the
requirements of Division 8400.

8103 General
(a) Subsurface Data

If it is found during the course of excavation that the load bearing strata differs from that shown on the
Drawings, the Contractor shall immediately notify the Engineer.
The Engineer shall be entitled, as often as he may deem necessary during the course of excavation,
to call upon the Contractor to perform additional foundation investigation and/or tests at or below the
respective foundation levels to establish safe bearing pressures and foundation depths.
(b) Channel preservation

Stream flow and preservation of marine and freshwater life shall be maintained at all times.
Access to cofferdams, artificial islands and piling platforms shall be accomplished without disrupting
the stream flow at the point of crossing unless otherwise specified in the Particular Specifications.
On completion of the work surplus excavated materials, including materials excavated from caisson
compartments and piles, materials used in cofferdams and other temporary works, as well as in-situ
material, shall be removed and disposed of by the Contractor to the original bed level or such lower
elevation as agreed to by the Engineer or required for stream channelization works.
8104 Cofferdams, Artificial Islands and Dewatering
(a) General
This clause covers the provision of access, including the construction of cofferdams, and draining the
excavations.
Where it is unnecessary to provide access in terms of sub-clause 8104(b), the Contractor shall be paid
separately for draining the excavations.
After Completion of the permanent works, all temporary works shall be completely removed, the
ground levelled and the site left neat. Where this is impracticable, such portions that have not been
removed shall be dealt with in accordance with the Engineer’s instructions.
(b) Access
Where temporary banks or artificial islands are constructed to provide access to the location where
structural members, piles or caissons are to be constructed, the banks or islands shall be adequately
compacted to a density that supports any plant and material without undue settlement which may have
a harmful effect on the end product.
The Contractor may use any material deemed by him to be suitable for constructing the islands. No
separate payment will be made in terms of items 81.02(b), 81.22, 81.24 and 81.47(b) for any
obstructions or hard materials occurring in the material used for constructing temporary banks or
artificial islands.
Designing and constructing any cofferdams shall comply with the requirements of the prevailing
version of the ERA Bridge Design Manual, Part 1 and the AASHTO LFRD Bridge Construction
Specifications. Prior to construction, the Contractor shall submit Drawings to the Engineer, which show
details of the cofferdams and the method of construction.
(c) Dewatering
The Contractor shall be responsible for preventing the ingress of water into excavations.

The preventative measures shall include the construction of proper drainage channels; diversion
channels; sumps; the supply and operation of the necessary bailing and pumping equipment; and the
construction of suitable watertight cofferdams.
The dewatering measures, with the exception of pumping, shall be maintained until the backfilling has
been completed.
Between the various construction stages pumping may be interrupted as agreed by the Engineer. Any
draining or pumping of water from cofferdams or the interior of any foundation enclosure shall be done
in such a manner as to preclude the possibility of any portion of the concrete materials being carried
away.
8105 Excavation Works
(a) General
This work shall include excavations required for the foundation of structures as well as for the
excavations required for existing bridges and culverts where these have to be demolished, extended
or modified; and are not provided for elsewhere in these Specifications,
The Engineer may require additional excavation to that described in the Contract to remove any
pockets of soft soil or loose rock. The resulting voids and any natural voids shall be filled with
Class 20/20 concrete complying with the requirements of Clause 8404 of these specifications; or other
material as instructed by the Engineer.
No trimming of the sides of the excavation shall be carried out within 24 hours of the placing of any
blinding concrete.
Any additional excavation below the bottom of foundations, including that resulting from removal of
material which the Contractor has allowed to deteriorate, shall be replaced with Class 20/20 concrete
complying with the requirements of Division 8400 of these specifications; or other material as
The sides of the excavation for foundations for structures shall either be vertical or sloped at a safe
angle for the material to be excavated. Except in rock, vertical sides shall be adequately supported at
all times to the satisfaction of the Engineer.
All practical measures shall be taken to prevent the ingress of surface water into the excavated
foundations. Any water collecting in the excavated foundation shall be removed as soon as possible
thereafter.
(b) Ground surface for excavation

Prior to commencement of any excavation, the Contractor shall notify the Engineer in good time to
ensure that measurements, cross sections and levels of the undisturbed ground can be taken in order
that an average ground surface level from which the excavation is to be measured can be established
and agreed upon between the Engineer and the Contractor.
(c) Excavation
Where, in the opinion of the Engineer, the casting of concrete against the excavated earth faces is not
permissible, or where formwork has to be provided, the extremities of the excavation, for purposes of
measurement and payment, shall be deemed to be the vertical planes parallel to, and 0.6m outside,
the perimeter of the member for which formwork is to be provided.

Where suitable stable material is encountered during excavation, that part of the trench or foundation
pit shall be excavated to the neat dimensions of the base unless directed otherwise by the Engineer.
Over excavation (over-break) in hard material shall be backfield with the same class of concrete as
that in the base or with mass concrete fill as specified or as directed by the Engineer.
Where blasting is required, the Contractor shall complete the entire foundation excavation before the
commencement of the construction of any permanent concrete work, unless otherwise approved by
the Engineer. The Contractor’s attention is drawn to the general requirements for blasting as specified
in Clause 1210.
Boulders, logs, or any other unsuitable material excavated shall be spoiled.
When hard material suitable for foundation is encountered at the foundation level, it shall be cut and
trimmed to a firm surface, either level, stepped or serrated, as required.
Where the material at the foundation level is soft material or hard material that deteriorates rapidly on
exposure, excavation to final grade and elevation shall not be made until just before the blinding layer
is placed.
Where, in the opinion of the Engineer, unsuitable material is encountered at foundation level, such
material shall be removed and replaced with foundation fill in accordance with Clause 8109 and as
(d) Classification of excavated material

Distinction shall be made for payment purposes between excavation in hard and soft material. All
excavation for the foundations of structures shall be classified in accordance with the following
classifications:
(i) Hard material

Material, which cannot be excavated except by drilling and blasting, or the use of pneumatic tools or
mechanical breakers shall be classified as hard material.
(ii) Soft material

All material not classified as hard material shall be classified as soft material.
(e) Blasting
Where blasting is permitted it shall be carried out in accordance with the requirements of the Contract
and the general requirements of Clause 1210 of these specifications.
(f) Deterioration of foundation excavations

Where the bottoms or sides of excavations in which bases are to be cast are softened due to
negligence on the part of the Contractor in allowing storm or other water to enter the excavations, the
softened material shall be removed and replaced with foundation fill as directed by the Engineer at the
Contractor's expense.
(g) Excavation safety

The Contractor shall take the necessary precautions to safeguard the stability and safety of the
excavations and adjacent structures.
The personal safety of any person shall not be placed in jeopardy nor shall any situation be allowed to
arise which may result in damage of whatsoever nature.
The Contractor’s attention is draw to the general safety requirements of Divisions 1200 and 1600 of
these specifications.

(h) Inspection
No concrete shall be placed before the excavation has been properly cleaned, and inspected and
(i) Excavation by hand

Where circumstances prevent the use of mechanical excavators and material can be removed only by
hand implements, the Engineer shall authorise the supplementary payment to the Contractor for such
work at the tendered rates for excavation by hand should the Engineer be satisfied that the Contractor
had been unable to prevent the necessity for excavation by hand by proper planning and
precautionary measures.
The supplementary rate for excavation by hand shall not apply to minor finishing or clearing jobs in
excavations which are otherwise being done by mass excavation plant.
(j) Trench Method Excavation for Box/Slab Culverts
(i) Depth of Excavation

The minimum cover for box/slab culverts shall be 100mm or such greater height as may be shown on
the Drawings, whichever is the greater.
The minimum amount by which the excavation is to exceed the proposed level of the underside of the
culvert invert slab shall be 250mm in the case of culverts with pre-cast invert slabs. In the case of
culverts with cast in-situ invert slabs, the excavations shall exactly accommodate the invert slab.
(ii) Width of Excavation

Where it is required to backfill the trench with concrete as described hereinafter, the width of
excavation shall be equal to the total outside width of the culvert portal plus 0.5m for both single and
multiple openings. In the case of rectangular culverts up to 1.2m span, which are located so that the
tops of the culverts are in or just below the sub-base layer, the Engineer may require that the
excavation width shall be the net width of the cast in-situ invert slabs or the net width of the pre-cast
invert slabs plus 100mm.
Where backfilling is to be done with soil or gravel material, the width of excavation shall be the outside
width of the portal plus 500mm on either side, for both single and multiple culverts.
8106 Foundations
As a result of possible variations of anticipated foundation conditions, the dimensions and foundation
levels specified or shown on the Drawings may have to be varied during construction.
The Engineer has the full and absolute power in terms of this contract to order such variations and to
specify the actual foundation level for each foundation fill, base, or caisson during construction and his
decision shall be final and binding on the Contractor.
The Contractor shall not be entitled to any additional payment in consequence of any such variation in
the dimensions or foundation depths over and above that provided for in Clause 8116 regardless of
the stage of construction at which the instruction to vary the dimensions or foundation depths is given.
However, if in consequence of such variation order the Contractor is compelled to substitute machines
and equipment with other machines and equipment in order to successfully complete the work, the
Engineer may, at his discretion, reimburse the Contractor for additional expenses incurred provided
that the original machines and equipment were suited to the work required prior to the variation order
being issued.

No base, caisson, or pile shall be founded unless authorised by the Engineer. Each foundation level
shall be accurately measured and recorded.
The term “foundation level” used in these Specifications shall be deemed to have the following
meanings in respect of:
 Foundation fill: The surface of the in-situ material that has been prepared to receive
foundation fills.
 The underside of the base.
 The underside of the under ream, bulbous base or rock socket; the tip of the pile shoe or lower
pile end, as may be relevant.
8107 Utilisation of Excavated Material

Excavated material and material recovered from temporary work shall, so far as it is suitable, be
utilised for backfill.
Material unsuitable for use as backfill or in excess of the quantity required to complete the backfill shall
be spoiled or utilised as directed by the Engineer.
Excavated material not used for backfill or not taken to spoil but used in the construction of
embankments or other parts of the work, as directed by the Engineer, will be paid for under foundation
excavation as well as under the relevant item for the purpose for which it is used.
Excavated and stockpiled material shall be deposited so as not to endanger the uncompleted
structure, either by direct pressure or indirectly by overloading the banks contiguous to the structure or
in any other way.
8108 Backfill and Fill near Structures
(a) General
In placing backfill and fill, the following precautions shall be taken:
 The material shall be placed simultaneously, in so far as is possible, to the same elevation on
both sides of an abutment, pier, or wall where appropriate.
 If conditions require placing backfill or fill appreciably higher on one side than the other, the
additional material on the higher side shall not be placed until authorised by the Engineer and
preferably not until the concrete has been in place 14 days; or until tests show that the
concrete has attained sufficient strength to safely withstand any pressure created by the
backfill or fill or the method of construction.
 The material behind abutments restrained at the top by the superstructure (eg portal type
structures) shall be placed as stated on the Drawings or as directed by the Engineer.
 The material behind the walls of concrete culverts shall not be placed until the top slab is
placed and cured, unless otherwise authorised by the Engineer.
(b) Backfill
Excavated areas around structures shall be backfilled with approved material in horizontal layers, not
exceeding 150 mm in depth after compaction, to the level of the original ground surfaces.
Each layer shall be moistened or dried to optimum moisture content for the material and compacted to
a density of not less than 93% modified AASHTO.

(c) Fill
To prevent wedge action against the structure and bounding slopes, the slopes shall be benched or
serrated.
In no case shall the toe of the bounding fill be closer to the concrete face than the height of the
exposed face of the abutment or wall.
(d) Select Granular Backfill

Select granular backfill shall be sound, durable, granular material free from organic matter or other
deleterious material (such as shale or other soft particles with poor durability).
Select granular backfill shall conform to the following requirements:
 Gradation according to Table 8108/1.

 Los Angeles Abrasion to AASHTO T-96: 50% max.
 Liquid limit, according to AASHTO T89: 30 max.
 Electrochemical requirements:
 Resistivity to AASHTO T-22: 3000   cm min.
 pH to AASHTO T-289: 5.0 to 10.0
 Sulphate content to AASHTO T 290: 1000 ppm max.
 Chloride content to AASHTO T 291: 200 ppm max.
(Note: Tests for sulphate and chloride content are not required when pH is between 6.0 and 8.0 and the resistivity is greater than
5000 ohm centimetres.)
Table 8108/1: Select Granular Backfill Gradation
Per cent by Mass Passing Designated Sieve

Sieve Size
(AASHTO T27 and T11)
100 mm 100
75 mm 75 – 100
75 m 0 – 15
(e) Fill within restricted areas

The portion of the fill within 3m of the concrete faces of the structure and the whole of the spill through
portion, or the extent shown on the Drawings, shall be termed "fill within restricted area".
Fill within the restricted area shall comply with the requirements of Series 4000 except that it shall be
compacted to a density of not less than 93% of modified AASHTO density. In order to achieve the
specified density, the Contractor shall, where necessary, import material of suitable quality.
Payment in accordance with Pay Item 81.06 for the construction of fill within restricted areas shall only
be made when specifically provided for in the Bill of Quantities.
8109 Foundation Fill

If it is found during the course of excavation that the material at the indicated foundation depth does
not have the required bearing capacity as specified on the Drawings, the excavations shall be
extended at the discretion of the Engineer until satisfactory foundation material is encountered.
The Engineer reserves the right to order the Contractor to make up the difference in levels with
foundation fill.

Where the foundation fill consists of rock or crushed stone fill, it shall be constructed in accordance
with the requirements of the Particular Specifications or as directed by the Engineer.
Foundation fill consisting of granular material shall be constructed in layers not exceeding 150 mm in
thickness after compaction. Each layer shall be moistened or dried to optimum moisture content for
the material and compacted to a density of not less than 95% of modified AASHTO density.
Mass concrete fill to be used shall be of the class or mix as specified or directed by the Engineer.
Unless specified or directed otherwise by the Engineer, the minimum foundation fill consisting of rock
fill, crushed stone fill or compacted granular fill to be constructed shall be defined by a prism with plan
area coinciding with the lower base of a truncated pyramid the sides of which slope at an angle of 60º
with the horizontal from the underside of the footing or slab to the foundation level.
A concrete blinding of 75mm thickness and Class 15/20 concrete shall be placed underneath all bases
except where mass concrete fill is used or where authorised by the Engineer.
Where mass concrete is constructed under a base it shall be constructed accurately to the final levels
of the underside of the base.
8110 Bedding and Laying of Box/Slab Culverts

(i) Cast in-situ Invert Slab Culverts
Cast in-situ invert slab culverts are constructed as an inverted “U” on a concrete base foundation (or
bottom slab) and shall be constructed to the dimensions and at the locations as shown on the
Drawings or as directed by the Engineer. They shall be reinforced with steel reinforcement as detailed
on the Drawings.
When the foundation material is unsuitable or unable to provide adequate bearing capacity for the
culvert, a layer of fine granular material of a least 1m thickness shall be placed, if directed by the
Engineer, on the bottom of the excavation, levelled, compacted to 98% Modified AASHTO density and
trimmed to grade and line, to form a bed to receive the bottom slabs.
(ii) Precast Invert Slabs

A layer of fine granular material of at least 250mm thickness shall be placed on the bottom of the
excavation, levelled, compacted to 98% Modified AASHTO density and trimmed to grade and line to
form a bed to receive the pre-cast invert slabs.
The slabs shall be carefully placed on the prepared bed, true to line and grade, and bedded in such a
manner that they are uniformly supported on the bedding over their whole area.
(iii) Placing of Upper Portion of Culverts

The upper portion of box/slab culverts shall be placed accurately on the invert slabs, with a thin layer
of 1:3 cement/sand mortar between the contact surfaces to ensure a firm and uniform support.
Where two or more culverts are placed side-by-side to form a multi-barrel culvert, the space between
the culverts shall be filled with concrete up to the level of the top of the culvert. Where prescribed, filter
fabric shall be applied to the vertical outer faces in accordance with the details shown on the
Drawings.
8111 Grouting of Rock Fissures

Where specified, fissures in the rock below and around the base shall be sealed by pressure grouting
with a neat cement or sand-cement grout with a water:cement ratio as agreed to by the Engineer. The
extent of fissuring shall be established by water testing under pressure.
Holes of at least 40mm diameter shall be drilled in positions ordered by the Engineer and grout
pumped into these holes under suitable pressures.

Grouting shall be carried out in 3m stages to the maximum depth ordered. Care shall be taken to avoid
further fracturing of the rock strata due to excessive grouting pressures.
Grouting of rock fissures shall be carried out by specialized operators with proven experience in this
class of work.
8112 Foundation Dowels

Where required, foundation dowels of the specified material, diameter and length shall be installed at
the positions and to the dimensions shown on the Drawings or as directed by the Engineer.
After exposure, clearing and trimming of the rock formation, holes of not less than 40 mm diameter
and of specified depth shall be drilled into the rock into which the dowels shall be fox-wedged and
grouted with a 2:1, sand:cement grout.
8113 Foundation Lining

Where specified or directed by the Engineer, foundation lining shall be installed as described
hereinafter.
The Engineer shall have the right to order the use of a lining against the sides of excavations and the
underside of bases and slabs in lieu of formwork and concrete blinding.
All surfaces to be lined shall be covered with approved sheeting to provide a clean impervious layer.
The material shall be of sufficient strength to provide a durable working surface and to support the
concrete and reinforcement without tearing.
The joints between strips shall have a 150mm overlap and the lining shall be held firmly in position by
nails, pegs, etc.
Polyethylene sheeting of 0.15 mm thickness is generally considered adequate for use under
approach/run-on slabs and bases.
8114 Foundation Piling
(a) General
This section covers the construction of bearing piles of concrete or steel or a combination of these
materials.
(b) Piling Layout

The piling layout, the minimum pile size and/or bearing capacity and type together with the steel
reinforcement and class of concrete required shall be as detailed and specified on the drawing unless
otherwise specified in the Particular Specifications.
(c) Alternative Designs for Piling and Piling Layouts
(i) Submission
The priced Bill of Quantities submitted for alterative designs shall be complied strictly in accordance
with the relevant measurement and payment clauses of these specifications.
Where Pay Items defined in these specifications have been omitted, it shall mean either that the items
do not apply, or that where the Engineer requires work falling under such items to be done, it shall be
done without any cost to the Employer. The inclusion of "rate-only" items will not be permitted.

Where Pay Items not defined in these specifications are used, the measurement and payment
requirements for such items shall be specified in detail by the Contractor. In the absence of such
definitions, or in the case of any ambiguity, the interpretation of the Engineer shall be final and binding.
Except in piling-only contracts or where otherwise provided in the Particular Specifications, the
Contractor shall price the Bill of Quantities for the original design irrespective of whether or not an
alternative design is offered.
(ii) Design
The critical design-load combinations acting upon the underside and the centre of gravity of the pile
cap, the maximum permissible level of the pile cap, and the technical data required for designing
alternative piles and/or piling layouts, will be indicated on the Drawings.
Alternative designs shall comply with the provisions of the Contract and the following requirements:
 The Contractor shall submit with his tender a detailed description of the method of analysis
used in the alternative design of the piles and the pile-group layouts.
 The average length of pile and/or of the piles per group on which the quantities in the Bill of
Quantities for the alternative designs are based shall be stated in each case. The type of pile
offered shall be defined in terms of size, materials, working and ultimate load.
 The Contractor shall be responsible for (and shall bear the cost for) redesigning, drafting and
submitting the detailed Drawings for any structural element affected by the alternative pile
design. Any savings or additional cost caused by constructing such element as compared to
the original design shall be for the account of the Contractor.
 The Contractor shall, as specified in the Contract, submit to the Engineer at least three (3)
months prior to work being commenced, Drawings detailing the piling-group layout and piles,
incorporating such amendments to his original design as may be required by the Engineer;
and Drawings detailing the amendments required to the pile-capping slab dimensions and
reinforcement as a result of the layout of the piles, all as applicable.
 No work of any nature shall be commenced on the piling until the Drawings have been
submitted to, and have been approved by the Engineer in writing.
 After approval of the Drawings, no departure shall be made without authorisation by the
Engineer.
 Where the alternative piles fail in regard to the load test specified in sub-clause 8114(v) of
these specifications, the Contractor shall be responsible for the cost of the work required for
improving the piles and pile layout so as to comply with the design requirements.
(iii) Basis of payment

Where the quantities in the Bill of Quantities referred to in sub-clause 8114(c)(i) differ from the number
of piles and the average pile length given in the submission for the alternative pile design, the
Engineer shall accept the sum in the said Bill of Quantities, correct the quantities, and adjust the rates
for the applicable Pay Items accordingly.
In addition to these corrections, the Employer, through the Engineer, shall be justified in using one of
the following methods for paying for piles constructed in accordance with the alternative design:
 Method 1
The Employer may check the alternative designs, calculate the quantities and adjust the rates as set
out in the first paragraph of sub-clause 8114(c). The Employer will then pay for the work in accordance
with the actually measured quantities.

 Method 2
The Employer may use the following formulae for calculating the quantities under Pay Items 81.17 to
81.35 for payment:
Np = Nd
Lp = Nd.Ld + Nb(Lb-Ld)K for Nd > Nb
and
Lp = Nd.Ld + Nd(Lb-Ld)K for Nd < Nb

𝐿𝑏 𝐿𝑑
𝐾= for Ld ≥ Lb and for Ld ≤ Lb
𝐿𝑑 𝐿𝑏
Where: P = paid, d = designed and, b = built.
The term "units" means items of work measured and paid for in the respective Pay Items such as
piles, raking piles, casings, under-reams and concrete.
Np = number of "units" measured and finally paid for in a particular pile group.
Nd =number of "units" provided for in the tender for the alternative design in the same pile group.
Nb = number of approved and accepted "units' finally installed in the same pile group.
Lp = the length of the "units" measured and paid for or the length to be used in calculating quantities
which are a direct function of the length of the "units" for the same pile group.
Ld = the average length of the "units" provided for in the tender for the alternative design in the same
pile group.
Lb = the average length of the Nb "units" actually installed in the same pile group.
The values Nd and Ld for each pile group for which an alternative design has been offered shall be
supplied with the tender by the Contractor for the respective "units".
The values of Nd, Nb, Ld and Lb for each pile group to be used in the formulae for determining the
quantity for a particular Pay Item shall relate only to the piles the item measured.
(d) Details to be furnished by the Contractor

In all cases where the choice of the type of pile to be used is left to the Contractor, full particulars,
specifications, calculations and Drawings of the piles proposed for use by the Contractor shall be
submitted with the tender.
The Contractor shall submit the following information to the Engineer, two (2) weeks before any piles
are driven or holes are formed:
 How the piles and casings will be installed or the holes will be formed;
 How the piles and casings will be installed or the holes will be made through identified
obstructions;
 The mass of the hammer;
 The set during the last ten blows;
 The expected size of the bulbous base, under-ream, rock socket, etc., if any;
 How mud, water and loose or soft material is to be removed in the case of cast in-situ piles;
 How concrete or grout is to be placed and compacted in the case of cast in-situ piles;

 How reinforcing steel is to be placed and held in place during placing and compacting the
concrete in cast in-situ piles;
 Details of permanent casing, if any;
 The mix design for the concrete, together with an adequate quantity of cement and aggregate
to enable the Engineer to conduct the necessary tests.
(e) Pile-installation Frames and Equipment

The pile-installation frames and equipment used for driving the piles or forming the holes for other
methods of sinking the piles shall be in a good working condition for the prior approval of the Engineer;
and shall comply with the relevant legal provisions.
The Contractor shall supply the necessary equipment, gear and instruments required for the
prescribed investigations and inspections.
The installation frames shall be so designed as to ensure that piles can be installed in their proper
positions and true to line and slope.
(f) Piling Platforms

Piling platforms shall include the prepared in-situ material or artificial islands or any structure
(excluding the piling equipment) constructed for gaining access to the position where the pile is to be
installed and for carrying out the piling operations.
Structural piling platforms shall be rigid, and floating barges used for piling operations shall afford
sufficient stability to enable piles to be properly installed.
On completion of the piling, the Contractor shall remove all the artificial, constructed platforms and
reinstate the site to the satisfaction of the Engineer.
(g) Setting Out

The Contractor shall set out the pile positions and shall stake these positions with a durable marker.
Where the level from which the piling is undertaken is above the underside of the pile cap, due
allowance shall be made for the offset of raking piles at the underside of the pile cap to ensure they
are in the correct position.
(h) Ground Surface of Foundation Piling

Before starting any piling work, the Contractor shall notify the Engineer in good time to ensure that
levels of the ground surface are taken in order that an average ground surface from which the piling is
to be measured can be established and agreed on by the Engineer and the Contractor.
Where foundation piling at a site is preceded by excavation or the construction of fill, the surface from
which the piling is to be done shall be formed as near as possible to the underside of the pile cap as
(i) Cast in-situ concrete piles
(i) Reinforcement
Reinforcement shall not be placed in the pile bores until immediately before concreting.
Before the reinforcement is placed in position, all mud, water, and any loose or soft material shall be
removed from the bore.
Steel reinforcement shall be accurately maintained in position without damage to the sides of the bore
or the reinforcement itself.

Spacers shall be used to keep the reinforcing steel at the required distance from the inside face of the
pile casing and wall of the pile bore but shall not create zones through which aggressive ground water
may penetrate to the reinforcement.
Pile reinforcement will not be shown in the bending schedules.
Only the number, diameter and type of bars and their arrangement will be shown on the Drawings.
The Contractor may replace the bars shown on the Drawings with bars of different diameters and
spacing and of different types, on a basis of equivalent strength with the approval of the Engineer..
The reinforcement shall be assembled in cages, which shall be sufficiently robust to prevent their
permanent deformation during handing. In the case of cast in-situ piles, the inner sides of the cages
shall be kept open in view of the unrestricted placing of concrete therein.
The longitudinal bars shall project above the cut-off point by the distance shown on the Drawings, or
by 40 times the bars diameter if no dimension has been given.
Splicing the reinforcement may be ordered, and the Contractor shall keep available on the site
sufficient steel reinforcement so that an additional length of pile reinforcement can be assembled
whenever necessary.
The assembly of additional reinforcement shall be carried out expeditiously and before any concreting
of any specific pile commences.
If splices have to be provided, the longitudinal bars shall overlap for a distance of 40 bar diameters, or
as required by the Engineer.
(ii) Concreting of Piles

The concreting of the piles shall not commence prior to the Engineer’s approval thereof.
Except in self-supporting pile bores, a temporary or permanent casing shall be installed for the full
depth of the pile to prevent lumps of material from falling from the sides of the bore into the concrete.
Where concrete is to be placed under the drilling mud, the temporary casing may be omitted, except at
the top end of the bore.
The concrete shall be so proportioned as to be of sufficient strength, but shall be sufficiently workable
to enable it to be properly placed; and, where self-compacting concrete is not used, it shall be
thoroughly compacted by approved means.
Extraction of the temporary casing during placement of the concrete shall be such that no damage is
caused to the pile and the advancing concrete level is at all times kept considerably above the
temporary casing’s trailing edge.
Concrete shall generally be placed in the dry but where this is impractical it shall be placed by tremie.
The requirements of Clause 8406 of these specifications together with the following requirements shall
apply when concrete is placed under water by tremie:
3
 The cement content shall be not less than 400 kg/m and the slump shall be such that the
concrete of the specified strength and desired density can be obtained.
 The hopper and tremie shall be a closed unit, which cannot be penetrated by water.
 The tremie shall be at least 150 mm in diameter for 19.0 mm aggregate and larger for larger
aggregates.
 The concrete shall be so placed as to prevent the mixing of water and concrete. The tremie
shall at all times penetrate into the concrete.

 Placing the concrete in that part of the pile below the water level in the casing shall be done in
one operation, and the same method of placing the concrete shall be maintained throughout.
 All tremies shall be thoroughly cleaned before and after use.
 Before placing the concrete in the water, the Contractor shall ensure that no silt or other
materials have collected at the bottom of the bore, and where drilling mud is used, the
Contractor shall ensure that no drilling mud suspension with a relative density exceeding 1.3
has collected at the bottom of the bore.
 Whenever practical, concrete shall be placed in a manner that will prevent segregation.
(j) Precast Concrete Piles

The piles shall be of reinforced or pre-stressed concrete and shall be manufactured, handled, stored
and installed in accordance with the prevailing version of the AASHTO LRFD Bridge Construction
Specifications, unless otherwise specified herein or in the Particular Specifications.
(i) Manufacture
The piles may be manufactured in a factory or a casting yard on the site of the works. The Contractor
shall ensure that the factory or casting yard shall at all reasonable times be accessible for inspection
by the Engineer.
The relevant requirements of Division 8400 shall apply to the concrete work.
Transverse and longitudinal reinforcement shall comply with the requirements of the prevailing version
of the ERA Bridge Design Manual.
The piles shall be cast on a rigid horizontal platform in approved moulds. Particular care shall ensure
that the reinforcement, coupler sockets and pile shoes are accurately in position. Adequate provision
shall be made for lifting the piles.
Each pile shall be clearly marked with the date of casting, a reference number, and from the tip of the
pile at metre intervals, with distance marks.
Piles shall be cured for a period sufficient to develop the strength required to withstand, without
damage to the pile, the stresses caused by handing, transporting, storing and driving. The piles shall
not be driven before the concrete in the pile has attained the specified strength.
(ii) Handing, Transport and Storage

Care shall be taken at the stages of lifting, handling and transporting to ensure that the piles are not
damaged or cracked.
Piles shall be stored on firm ground, which will not settle unequally under the weight of the stack of
piles. The piles shall be placed on timber supports, which are truly level and spaced so as to avoid
undue bending in the piles. The supports in the stack shall be located vertically above one another.
(iii) Lengthening of Precast Piles

Piles shall be lengthened where required by such means and methods as approved by the Engineer.
Care shall be taken to ensure that the additional length of pile joined is truly axially in line with the
original pile within the tolerance requirements for straightness set out in Division 10100 of these
specifications.
Driving shall not be resumed until the pile extension and any bonding agent used has attained the
required strength.
(k) Steel Piles

Hollow steel piles may be filled with cast in-situ concrete and, provided that adequate connections are
provided between the steel and the concrete with a view to transferring the load, the concrete may be
deemed to assist in carrying the load.
Wherever steel piles are used, they shall be given a protective coating of bitumen or synthetic resins
to the satisfaction of the Engineer, or as specified.
The cross-sectional area of the steel shall be adapted to the aggressiveness of the sub-surface
conditions to compensate for possible reduction in the pile wall thickness caused by abrasion and
corrosion during the service life of the pile.
Steel piles shall be used only where permitted by the Engineer.
(l) Driving Piles
(i) Pile-installation frames

Piles and pile casings shall be driven with a gravity hammer, a rapid-action power hammer or by other
approved means.
Pre-stressed concrete piles shall be driven with a hammer with a mass of at least equal to that of the
pile. Other piles shall preferably be driven by a hammer with similar mass characteristics. The hammer
shall not, during driving operations, damage any permanent component of the pile.
Pile driving leaders shall ensure freedom of movement of the hammer and shall be held in position to
ensure adequate support for the pile or pile casing during installation. Inclined leaders shall be used
for installing raking piles.
The heads of precast concrete piles shall be protected with packing of resilient material, care being
taken to ensure that it is evenly spread and held in place. A helmet shall be placed over the packing,
and a dolly of hardwood or other material not thicker than the diameter of the pile shall be placed on
top.
(ii) Water Jetting

The Contractor may employ water jetting to install piles in granular material.
Jetting shall be discontinued before the leading end of the pile reaches of depth of 80% of the
anticipated final depth or a depth as agreed with the Engineer.
After jetting, piles or their casings shall be driven to the required depth, level or set.
(iii) Installation Sequence

Unless otherwise specified or ordered, the sequence for installing the piles shall be left to the
Contractor.
However, the sequence for driving the piles in a group shall be programmed to minimise the creation
of consolidated blocks of ground into which piles cannot be driven or which cause fictitious penetration
values.
Piling shall generally commence at the centre of the group and be progressively extended to the
perimeter piles unless otherwise agreed on by the Engineer.
The installation of piles shall be undertaken in such a manner that structural damage, distortion or
positioning defects will not be caused to previously installed piles or casings.
(iv) Heaving of Piles

In soils in which the installation of piles may cause previously installed piles to heave, accurate level
marks shall be placed on each pile immediately after installation and all piles that have heaved shall
be re-driven to the required resistance, unless re-driving tests on neighbouring piles have shown this
to be unnecessary.
Piles shall not be concerted neither shall any pile-capping slab be constructed until the piles within a
heave-influence zone have been re-driven as required.

(v) Bulbous Bases

Where required, bulbous (enlarged) bases shall be formed after the driven casing has reached the
required depth.
The base shall be formed by progressively displacing the surrounding subsoil with concrete placed by
the repeated action of a gravity hammer.
The size of the base will depend on the compressibility of the surrounding subsoil but shall in no case
have a diameter of less than 1.5 times the diameter of the pile.
(vi) Piling Alignment

Where the inclination of a precast concrete pile deviates from the correct slope during installation, the
pile shall not be forced into the correct position, and the slope of the guiding frame shall be adjusted
so as to coincide with the actual inclination of the pile to preclude the bending of the pile.
Where the verticality or the inclination of the installed pile falls outside the specified tolerances, the pile
will be classified as being defective.
(m) Augering and Boring
(i) Auger and Bore Pile Holes

The augering and boring of piles shall be carried out as expeditiously as local conditions permit taking
due account of services or other restrictions on the site.
Holes shall be cleaned after augering and boring to obtain a clean and level surface.
Where indicated by the Engineer, suitable casing shall be installed in those parts of the augered holes
where the sides are in danger of caving in before the concreting has been completed.
During extraction of the casing, care shall be taken to avoid lifting the concrete and damaging the pile.
The use of water for augering and boring holes shall not be permitted unless approved by the
Engineer.
Surface water shall not be allowed to enter the hole.
(ii) Under-reaming
Where required, the holes shall be enlarged or belled out to form an under-ream. The material
excavated shall be removed in a manner, which will not damage the walls of the hole.
The shape of the under-ream shall be a truncated cone of which the base diameter depends on the
bearing capacity of the founding material, but it shall be not less than twice the shaft diameter.
The base angle of the cone between the inclined face and the horizontal plane shall be not less than
60º.
Full safety measures shall be enforced to protect workmen working at the bottom of the pile hole.
(iii) Bulbous Bases

Bulbous bases shall comply with the requirements of sub-clause 8114(l)(v).
(iv) Hole Inspections

Immediately before the reinforcement is to be installed or the concrete placed, the Engineer shall be
informed thereof with a view to inspecting the pile holes.
When piles are to be under-reamed, the excavation shall be inspected twice by the Engineer, firstly to
ascertain that suitable founding material has been obtained before under-reaming may start, and
secondly, after the under-reaming has been completed for approval to be given by the Engineer for
casting the pile.

(n) Rock Sockets

Where required, rock sockets of the required dimensions shall be located in rock formations for
transmitting the specified load. The rock formation shall be of adequate strength, quality and thickness
to support the rock sockets.
(o) Obstructions
(i) Identified Obstructions

Identified obstruction shall mean any obstruction described on the Drawings or in the Particular
Specifications and for which provision for payment has been made in the Bill of Quantities in respect of
penetrating the obstructions.
(ii) Unidentified Obstructions

Where provision has been made in the Bill of Quantities in terms of Pay Item 81.21 for penetrating
identified obstructions and obstructions not described are encountered, such obstructions shall be
classified as unidentified obstructions and the penetration of such obstructions shall be paid for under
item 81.22 subject to the condition that the rate of penetration drops to below that achieved for
identified obstructions when the same method and effort are used or subject to additional methods and
effort over and above those required for identified obstructions being required for penetrating the
obstructions.
OR
Where no provision has been made in the Bill of Quantities for penetrating identified obstructions and
obstructions are encountered and, after resorting to the methods specified in the submission in terms
of sub-clause 8114(d), it is found to be impossible to form the holes in the proper positions and at the
proper inclinations and depths; and the Contractor has to resort to additional methods for forming the
pile holes successfully; such obstructions shall be classified as unidentified obstructions and paid for
under Pay Item 81.23.
(iii) Classification of Materials

For piling only the following classification of materials shall apply to the identification and description of
obstructions:
 Matrix: The matrix shall comprise that part of the material which will pass through a sieve with
50 mm x 50 mm openings.
 Coarse gravel: Coarse gravel shall comprise that part of the material (stones, pebbles,
cobbles, etc.) which will pass through a 200 mm x 200 mm opening, but will not pass through
a 50 mm x 50 mm opening. The gravel shall be obtained from material with at least class R2
hardness as given Table 8102-1 of these specifications.
 Boulders: Boulders shall mean any rock mass with a hardness of at least class R2 which will
pass through a square opening with dimensions equal to the maximum size boulder specified
in the Bill of Quantities but will not pass through a 200 mm x 200 mm opening.
 Rock Formation: A rock formation shall be any rock mass with a hardness of at least class
R2 which will not pass through a square opening with dimensions equal to the maximum size
boulder specified in the Bill of Quantities.
Where a boulder is cut through and part of it is left embedded in the wall of the hole, such boulder
obstruction shall be classified as rock formation.
(p) Driven Displacement and Prefabricated Piles

Where obstructions make it difficult to install driven displacement and prefabricated piles in the
positions and at the inclinations shown; and to the proper lengths by the methods specified in the
submission in terms of sub-clause 8114(d), the Contractor shall resort to additional methods, which
are suitable for the type of pile.
If the successful installation of a pile proves to be impossible after such methods have been tried, the
Engineer may order an additional pile or piles to be installed.
All such work and additional piles shall be paid for in accordance with the tendered rates where
applicable, or where they do not apply, under Pay Item 81.23.
Where identified or unidentified obstructions are encountered when shaping holes for piles, payment
for penetrating the obstructions shall be made against the appropriate Pay Items.
(q) Determining Pile Lengths

The design of the piles and pile groups, and the quantities in the schedule of quantities are based on
the subsurface data shown on the Drawings.
The Engineer will determine the depth of piles as work proceeds.
Where variations in the subsurface conditions occur as regards the material and height of the water
table, the Engineer shall be informed immediately.
If the Contractor is not satisfied that the piles will be capable of carrying the specified loads at the
depth determined by the Engineer he may, in consultation with the Engineer, lengthen the piles to
reach a suitable founding depth.
Where the Engineer and the Contractor cannot agree on the founding depth, the Engineer may require
the Contractor to:
 Undertake additional foundation investigation and/or core drilling in accordance with sub-
clauses 8103(a) and 8114(u) respectively and/or
 Install one or more test piles and conduct a load test in accordance with sub-clause 8114(v).
The Engineer will prescribe the positions for each test pile. Test piles shall comply with the
specified requirements for piling.
(r) Piling Data

The following data on each pile installed shall be recorded in a form prescribed by the Engineer:
 The effort used for driving the pile and the resistance to penetration at founding level.
 A description of subsurface material, the presence of ground water and the quality of material
on which the pile is founded.
 The quality of the materials used in the construction or manufacture of the pile, as well as of
the permanent casing if used.
 The method of placing and compacting the concrete in cast in-situ piles.
 The method of founding of the piles e.g. bulbous bases, under-reams, rock sockets, etc. and
their dimensions.
 The maximum working load of the pile in the Service Load state.
 The length of the pile and the accuracy of installation in respect of position and inclination.
 Nominal dimensions and type of pile.
 Length and details of any temporary and permanent casings used.
(s) Stripping the Pile Heads

Precast piles shall be installed to a level of at least 1m above the cut-off level, and cast in-situ piles
shall be cast to a level of at least 150mm above the cut-off level.
The excess concrete shall be so stripped off that only sound concrete will project into the pile-capping
slab.
Before a pile head is stripped, the cut-off plane shall be marked by cutting a 20mm deep groove with a
grinding machine along the full circumference of the pile.
Heavy concrete demolishing equipment may not be used for the stripping of pile heads.
All loose aggregate shall be removed from the cut-off plane.
The concrete shall be so stripped off that the pile below the cut-off level will not be damaged, or,
should defective concrete be found in the completed pile, the damaged or defective concrete shall be
cut away by the Contractor at his own cost and replaced with new concrete well bonded to the old
concrete, or the pile shall be replaced as directed by the Engineer.
The main reinforcement of the piles shall extend at least 40 times the diameters of the reinforcing bar
beyond the cut-off level into the pile-capping slab. This reinforcement shall be left straight unless
otherwise directed by the Engineer.
The cut-off level for piles shall be the level shown on the Drawings.
(t) Construction of Pile-capping Slab

The Contractor shall not construct the pile-cap before the Engineer has confirmed, in writing, that all
the relevant load tests have been completed and the piles have been accepted.
(u) Core Drilling

The Engineer may instruct core drilling to be carried out with a view to obtaining cores of the founding
formation and/or of the concrete in the completed structural member. In the case of piling, the core
drilling may precede the piling or may be done through the completed pile, as specified, or as
The Contractor shall supply the necessary construction plant on the site for drilling under the above
conditions. The plant and techniques used shall be suitable for ensuring 100% core recovery.
The diameters, depths and lengths of the cores shall agree with the specifications or the instructions of
the Engineer.
The Contractor shall keep accurate records of the drilling, which, together with the cores, shall be
handed over to the Engineer.
The cores shall be placed in the correct sequence in a clearly identified wooden core box with a lid.
(v) Load Test
(i) General
The Engineer may order certain selected piles to be load tested.
The procedure for loading tests shall comply with the requirements of Division 10112(c) of these
specifications. During the period of testing, driving of other piles, which may affect the testing, shall
cease.
No working pile shall be used as an anchor pile. Where another pile or earth anchors are required for
providing reaction, they shall be so placed as to have a minimal effect on the test results.
The Contractor shall provide the complete testing assembly, the necessary plant, equipment,
instruments and labour for carrying out the test and for determining accurately the settlement of the

piles under each increase or decrease of the load. The test assembly, plant, equipment and
instruments used shall be subject to the approval of the Engineer.
Within two (2) days of having completed the tests, the Contractor shall supply the Engineer with the
test results in the form graphs showing plots of load against settlement; load against time; and
settlement against time.
(ii) Loading
The maximum test load applied shall be equal to twice the specified working load or the ultimate test
load, whichever shall be the smaller.
The maximum working load shall be half of the maximum test load or the test load, which corresponds
with the allowable settlement, whichever shall be the smaller.
The allowable settlement shall be as specified on the Drawings.
(iii) Ultimate Test Load

The ultimate test load in the compression load test shall be the load where settlement suddenly
increases disproportionately to the load applied.
The ultimate test load in the tension-load test shall be the load where upward movement suddenly
increases disproportionately to the load applied or the load producing a permanent displacement of
10 mm at the top of the pile, whichever is the smaller.
(w) Defective Piles

The test piles and the piles represented by the test pile shall be classified as defective if shown in
terms of sub-clause 8114(v) to have a maximum working load of less than the specified working load,
or to exhibit excessive settlement.
Defective piles shall also include piles damaged beyond repair, piles with structural defects, or piles,
which do not comply with the tolerance requirements of Division 81100 of these specifications.
If required, the defective piles shall be corrected by the Contractor at his own cost, by applying one of
the following methods approved by the Engineer:
 Extracting the pile and replacing it with a new pile;

 Installing a new pile adjacent to the defective pile;
 Lengthening the pile to the correct length if defective in length only;
 Altering the design to fit in with the new conditions caused by the defective pile(s).
(x) Standing Time in Respect of Piles-installation Frames

Standing time shall only be paid for pile-installation frames standing during normal working hours as
laid down in the Conditions of Contract for such periods during which the pile installation work has
come to a standstill following an action by the Employer.
As soon as the pile-installation frames have come to a standstill, the Contractor shall inform the
Engineer, in writing, that he intends to claim standing time, and shall also furnish:
 Full particulars of the action which gave rise to the claim.

 A list of pile-installation frames in respect of which standing time will be claimed, complete with
date and time.
The period in respect of which a claim is lodged shall become operative from the moment when the
notice has been handed over to the Engineer and shall continue until the restriction has been removed
and normal procedure may be resumed.

8115 Caissons
(a) General
Caissons shall, for the purposes of these specifications, be hollow concrete vessels, which are wholly
or partly constructed at a higher level and lowered by internal excavation or kentledge to the desired
founding level to form structural bearing members.
Caissons may be of circular, rectangular or any other shape and may contain one or more excavation
compartments, all as detailed on the Drawings.
Unless otherwise specified hereafter, the provisions of the prevailing version of the AASHTO LFRD
Bridge Construction Specifications shall apply in regard to the construction of caissons.
(b) Construction and sinking

A firm horizontal base shall be prepared on which the cutting edge of the caisson shall be laid truly
horizontally.
The level of the base shall be determined and shall be agreed on by the Engineer and the Contractor
and shall serve as the ground surface from which the excavation inside the caisson will be measured.
Successive stages of the caisson shall be of convenient height, or as directed by the Engineer, and
shall be lined up accurately with the preceding stages.
All precast elements shall have properly constructed joints in accordance with the Drawings to ensure
that they fit snugly together.
For in-situ phase construction, all construction joints in the walls shall be reinforced and the joints shall
be made as specified in Clause 8407 of these specifications.
The lowest element of every caisson, which contains the cutting edges, shall be cured for at least four
(4) days or shall have reached a strength of at least 50% of the specified strength before sinking is
commenced. Subsequent elements shall be cast in sufficient good time to ensure adequate strength
for safely resisting the applied forces.
During constructing and sinking, the caissons shall be maintained truly vertically and kept in their
correct positions.
The position and inclination of each caisson shall be determined accurately by measurement after
every 2 m of sinking, or after sinking through the depth of one element, whichever distance is the
smaller.
With a view to eliminating excess friction, the Contractor may use bentonite or a similar lubricant, or a
water-jet system.
Excavation inside caisson compartments shall, unless otherwise specified herein, comply with the
provisions of clause 8105.
In multi-compartmented caissons, the excavation in any one compartment shall not be taken deeper
than 600 mm below that in any other compartment, except where necessary for correcting deviations.
Cutting edges shall be frequently inspected or probed to locate obstacles, which shall be removed
immediately.
The Contractor shall supply all grabs, pumps, diving gear and other plant required for sinking and
founding all caissons and shall allow the Engineer to use the diving gear and equipment for inspection
purposes.

The Contractor shall employ a competent diver to carry out work under water and shall make provision
in the rates tendered for the respective items for this cost.
Where the caisson strikes a hard inclined layer and work has to be carried out below the cutting edge,
such work shall be measured and paid for under the relevant items of Clause 8116, and, where no
applicable items exist, such work shall be paid for as extra work.
Should the Contractor wish to apply the pneumatic caisson method (with a compressed air chamber)
for construction, he shall furnish the Engineer with full details of the plant, equipment and method for
approval.
(c) Founding
The material at the founding level, if sloping and/or irregular, shall in so far as is possible be cut to as
nearly level a surface as possible until the entire cutting edge is evenly and firmly supported on the
material.
Subject to the approval of the Engineer, blasting may be used for this purpose. If blasting should be
resorted to, only light charges may be used and the caisson shall be protected against damage by
suitable cushioning being provided.
Should the sloping surface be of hard rock which cannot be cut or broken by any safe and feasible
means, the foundation shall be built up by means of a solid wedge of concrete which fills the entire
space between the bedrock surface and the horizontal plane, through the cutting edge. This concrete
shall be of the same class as that specified on the Drawings or in the schedule of quantities for the
concrete seal.
The rock or hard material on which the structure is to be founded shall be completely uncovered.
The founding surface shall be cleared of all loose material before inspection by the Engineer
immediately prior to casting the concrete seal.
No concrete shall be placed in the wedge or the seal before the Engineer has inspected and approved
the foundation. For this purpose the Contractor shall adequately dewater the caisson to enable the
Engineer to conduct the inspection.
In the event of a caisson not being vertical or in its correct position when it has reached the required
depth, or in the event of a caisson being cracked during the sinking process, the Contractor shall at his
own cost carry out the necessary remedial work to the satisfaction of the Engineer.
(d) Data
The Contractor shall provide the Engineer with a complete record of the types of material excavated
during sinking, together with the level at which each type of the material was found. In addition, a log
showing the rate of sinking shall be kept by the Contractor and furnished to the Engineer.
(e) Filling the caissons
(i) Concrete seal

The seal shall be constructed of mass concrete of the class specified and shall be placed in
accordance with the dimensions and levels shown on the Drawings or as prescribed by the Engineer.
If this seal cannot be placed in the dry and has to be placed under water, the method of placing this
concrete shall be approved by the Engineer.
The Contractor shall cease placing the concrete under water when sufficient concrete has been placed
to seal the foundation effectively.

After the concrete has been placed, the concrete seal and the head of water over it shall remain
undisturbed for a period of at least 7 days after which the caisson shall be dewatered by pumping for
inspection. If more water is still leaking into the caisson, the process of sealing as specified herein
shall be continued until the water level within the caisson does not rise at a rate exceeding 10 mm/hr.
The relevant requirements of Division 8400 of these specifications and Cause 8114 shall apply for
placing the concrete under water.
For concrete placed under water by methods other than by tremie, the cement content shall be 20%
more than the quantity required for ordinary concrete of the same mix but shall be not less than
3
450 kg/m of concrete.
(ii) Filling
Subsequent to inspection of the caisson compartments above the concrete seal, the compartments
shall be filled with sand. The sand shall be sufficiently wetted to obviate bulking.
The first 2.0m of filling above the concrete seal shall be lowered gently into position. The sand may
then be poured from the top and compacted sufficiently to prevent settlement while the cover slab
concrete is being placed.
The top of the sand fill within the caisson shall be finished off to the level specified below the
underside of the caisson cover slab.
(iii) Stripping
Where the walls of the caisson have been overbuilt, the concrete shall be stripped to the required level
without damage being done to the concrete below the cut-off level.
The longitudinal reinforcement of the caisson shall project above the cut-off level by a distance of at
least 40 times the bar diameter.
(iv) Concrete screed below the caisson cover slabs

A concrete screed of the specified thickness and class of concrete shall be provided to the level shown
on the Drawings over the area covered by the cover slab, including the area within the caissons on top
of the sand filling, except where the underside of the cover slab is being formed with formwork.

Item 81.01 Additional foundation investigations

(a) Fixed cost ....................................................................................................Provisional Sum
(b) Percentage allowed for overhead and profit on item 81.01(a) ...........................Percent (%)
A provisional sum is allowed in the Bill of Quantities to cover the cost of this work.
Item 81.02 Excavation of materials

(a) Excavation of soft material situated in the following ranges:
3
(i) 0 m to 2 m ..................................................cubic metre (m )
3
(ii) Exceeding 2 m to 4 m . ..................................................cubic metre (m )
3
(iii) etc in increments of 1 m depth …………………………………..cubic metre (m )
(b) For excavation in hard material irrespective of depth ................................. cubic metre (m³)

(c) For additional excavation required by the Engineer after the excavation has been completed
.....................................................................................................................cubic metre (m³)
The limits for the successive depth ranges shall be measured down from the average ground surface
(Sub-clause 8105(b)) to the agreed foundation level (Clause 8106).
The unit of measurement shall be the cubic metre of material, measured in the original position before
excavation. The quantity of excavation for each depth range shall be calculated from the neat outlines
of the base of floor and the depth of excavation completed within each range.
Irrespective of the total depth of the excavation the quantity of material within each depth range shall
be measured and paid for separately.
Supplementary payment for excavation by hand as specified in sub-clause 8105(i) shall be the full
compensation for incidentals for hand-excavating the materials instead of with mass-excavating
equipment.
At the face of any concrete for which formwork has to be provided an additional quantity of excavation
shall be measured to 450mm outside the concrete perimeter to provide for a working space.
Where foundation fill is constructed in an excavation, the quantity of excavated material measured for
payment shall be the material contained within the vertical planes through the lower base of the
truncated pyramid defined in Clause 8109 or as directed by the Engineer.
In no case shall any of the following excavation be included in the measurement for payment:
 The volume of excavation in excess of the above mentioned limits.

 The volume included with in the excavated road prism, contiguous channels, open drains etc,
for which payment is provided elsewhere in the Specifications.
 The volume of water or other liquid, except the volume of mud, muck or similar semi-solid
matter not resulting from construction operations and which cannot be pumped or drained
away.
The tender rate shall include full compensation for excavation in each class of material; the spoiling or
stockpiling of material; for any additional excavation the contractor may require for additional working
space outside the authorised limits; for trimming and cleaning the bottoms and sides of excavation for
strutting, shoring; and safeguarding excavations.
Excavation required for diverting, channelling or widening streams within 5m of concrete structures
shall be measured and paid for under item 81.02. Excavations beyond the 5m limit shall be measured
and paid for under the appropriate items of Series 3000 and 4000 of these specifications.
If, after any foundation excavation is completed, cleaned and trimmed ready for blinding, the Engineer
orders further excavations due to changed dimensions and/or foundation conditions, an extra over
payment (pay item 81.02(c)) on the additional excavation measured for payment shall be payable in
full compensation for any additional costs to the contractor over and above the normal excavation
costs.
Item 81.03 Access ......................................................................................................... lump sum

The tendered lump sum shall include full compensation for providing access, which inter alia, shall
include constructing temporary banks; artificial islands and/or cofferdams; their protection,
safeguarding and maintenance; draining and keeping dry the working areas including draining the
excavations within the access; and any incidentals in respect of work to be done below standing water.
An amount of 75% of the lump sum will be paid when the access has been constructed. The remaining
25% will be paid after the access has been removed.

Item 81.04 Drainage ......................................................................................................Lump Sum

Drainage where no access has been provided shall be measured in lump sum. Payment will be made
for this work by way of a lump sum for each structure or series of structures appearing separately in
the Bill of Quantities. The lump sum shall be paid on a pro rata basis as the work progresses.
The tendered lump sum shall include full compensation for drainage by pumping or in any other way
and for any other work necessary for keeping the excavation dry or for working in the dry.
Item 81.05 Backfill to excavations utilizing :

(a) Material from the excavation ............................................. .........................cubic metre (m³)
(b) Imported material .............................................................................. .........cubic metre (m³)
The unit of measurement shall be the cubic metre of backfill material measured in the excavations.
The quantity measured shall be calculated from within the neat outlines defined for the excavation
under pay item 81.02 and the height over which the backfilling is constructed.
The height shall be determined by the upper surface of the road prism or the reference ground
surfaces (Sub-clause 8105(b)) whichever is the lower.
The tendered rate for each cubic metre of backfill shall include full compensation for furnishing,
transporting and replacing all materials within the entire excavation; and for preparing, processing,
shaping, watering, mixing and compacting the material to the specified densities.
Item 81.06 Fill within restricted areas .............................................................. cubic metre (m³)
The unit of measurement shall be the cubic metre and the quantity shall be taken as the total volume
of material within the restricted area as defined in Sub-clause 8108 (e). The quantity shall not include
the volume of backfill which is measured and paid for under pay item 81.05 above.
The tendered rate shall include full compensation for all additional work necessary due to working in
the restricted area and for the increased density required in the restricted area.
Item 81.07 Overbreak in excavation in hard material ................................... square metre (m²)
The unit of measurement shall be the square meter of surface area of the vertical outer faces of the
bases.
The tendered rate shall include full compensation for the overbreak material removed from the
excavation; for the concrete fill in accordance with sub-clause 8105 (c); and any additional screeding
concrete required.
Item 81.08 Foundation fill

(a) Rock fill ..................................................................................................... .cubic metre (m³)
(b) Crushed stone fill ........................................................................................ cubic metre (m³)
(c) Compacted granular fill ............................................................................... cubic metre (m³)
(d) Mass concrete (Grade indicated) ............................................................... cubic metre (m³)
(e) Blinding layer (Grade of concrete and thickness indicated) .................... .square metre (m²)
The unit of measurement shall be the cubic metre of approved material placed and compacted below
the bases as specified or where directed by the Engineer.

The quantity of foundation fill to be measured for payment shall be the material contained within the
prism specified in Clause 8109 for minimum foundation fill to be constructed or to the outlines shown
on the drawings or as directed by the Engineer.
The tendered rate shall include full compensation for the procuring, furnishing, transporting, placing,
and compacting of the material.
Item 81.09 Establishment on site for the grouting of rock fissures ........................... Lump Sum
The tendered lump sum shall include full compensation for establishment on site and subsequent
removal of all special plant for the grouting of rock fissures and for carrying out operations, the cost of
which does not vary with the actual amount of work to be done.
This work shall be paid for as a lump sum, of which 75% will become payable when all equipment is
on the site and the first hole has been grouted, and the remaining 25% will become payable after all
the holes have been grouted and the equipment has been removed from the site.
Item 81.10 Move to and set up equipment at each hole to be drilled ..................Number (No)
The unit of measurement shall be the number (No) of positions to which the equipment for drilling and
grouting of rock fissures has to be moved and set up in position.
The tendered rate shall include full compensation for all costs involved in moving and setting up
equipment.
Item 81.11 Drilling of holes .......................................................................................... metre (m)

The unit of measurement shall be the meter of hole drilled.
The tendered rate shall include full compensation for drilling and cleaning of holes as specified.
Item 81.12 Grouting of holes .................................................................................................... kg

The unit measurement for grouting shall be the mass in kilograms of cement used in the grouting
operation.
The tendered rate shall include full compensation for providing and pumping into the drilled holes the
grout as specified by the Engineer.
Item 81.13 Doweling into rock:

(a) Drilling and cleaning ............................................................................ ..................metre (m)
(b) Supply and installation of dowel bars ................................................. ..............kilogram (kg)
The unit of measurement for the drilling and cleaning of holes in rock shall be the meter of hole drilled.
The unit of measurement for the dowel bars shall be the mass in kilograms of bars actually provided
and secured in position.
The tendered rate shall include full compensation for drilling and cleaning of holes, supplying,
positioning and grouting of dowel bars as specified.
Item 81.14 Foundation lining ......................................................................... square metre (m²)

The unit of measurement for foundation lining (type of material and thickness indicated) shall be the
square metre of concrete surface lined.
The tendered rate shall include full compensation for the procuring, furnishing, transporting and
placing of all material and for labour and incidentals required to complete the work as specified.

Item 81.15 Establishment on the site for piling .......................................................... lump sum
The tendered lump sum shall include full compensation for levelling the piling site; establishing on the
site and subsequently removing all structural platforms; rafts and all special constructional plant and
equipment for foundation piling; and for carrying out operations, the cost of which does not vary with
the actual amount of piling done.
This work will be paid for by way of a lump sum, 50% of which will become payable when all
equipment is on the site and the first pile has been installed. The second instalment of 25% of the
lump sum will be payable after half the total number of piles have been installed, and the final
instalment of 25% after all the piles have been completed and the equipment has been removed from
the site.
Item 81.16 Moving to, and setting up the equipment at each position for installing the piles
................................................................................................................. Number (No)
The unit of measurement shall be the number of positions to which the installation equipment has to
be moved and set up in position. The quantity measured shall be the number of piles installed plus the
number of piles re-driven on the instruction of the Engineer, plus any additional piles for load tests
which do not form part of a specific pile group.
The tendered rate shall include full compensation for all costs involved in moving and setting up any
equipment.
Item 81.17 Augered or bored holes for piles

With a diameter (diameter indicated) through material situated within the following successive depth
ranges:
(a) Augered holes:
(i) 0 m up to 10 m ............................................................................ ..............metre (m)
(ii) Exceeding 10 m and up to 15 m ................................................. ..............metre (m)
(iii) etc in increments of 5 m depths. .................................................…………metre (m)
(b) Bored holes
(i) 0 m up to 10 m .......................................................................................... metre (m)
(ii) Exceeding 10 m and up to 15 m ............................................................... metre (m)
(iii) etc in increments of 5 m depths ..................................................…………metre (m)
(Sub-clause 8114(h)) to the agreed founding level (Clause 8106).
The unit of measurement shall be the metre of hole, including the depth of the bulbous base formed,
as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a
sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base.
Irrespective of the total depth of the hole, the quantity within each, depth range shall be measured and
paid for separately.
The tendered rates for forming augered holes shall include full compensation for boring, supplying,
installing and extracting the driven temporary casing as well as for disposing of surplus material
resulting from the hole having been formed.

Item 81.18 Driving the temporary casing for driven displacement piling systems for forming
holes for piles
With a diameter (diameter indicated) through material situated within the following successive depth
ranges:
(a) 0 m up to 10 m ..................................................................................................... ...metre (m)
(b) Exceeding 10 m and up to 15 m............................................................................... metre (m)
(c) etc in increments of 5 m depths ................................................ ...............................metre (m)
(Sub-clause 8114(h)) to the agreed founding level (Clause 8106).
The unit of measurement shall be the metre of hole plus the depth of bulbous base formed, as may be
applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere,
the volume of which shall be equal to the quantity of compacted concrete in the bulbous base.
Irrespective of the total depth of the hole, the quantity within each depth range shall be measured and
The tendered rates shall include full compensation for supplying, driving and subsequently extracting
the temporary casing.
Item 81.19 Manufacturing, supplying and delivering prefabricated piles ................ metre (m)
The unit of measurement shall be the metre (m) of accepted prefabricated pile (type and size
indicated) delivered on the site in accordance with the Engineer's written instructions.
The tendered rate shall include full compensation for supplying all the materials, manufacturing,
transporting and delivering to the point of use and handling the prefabricated piles.
Item 81.20 Installation of prefabricated piles

Type and size indicate, through material situated within the following successive depth ranges:
(a) 0 m up to 10 m .................................................................................................... . metre (m)
(b) Exceeding 10 m and up to 15 m............................................................................ metre (m)
(c) etc in increments of 5 m depths .......................................................................... . metre (m)
(sub-clause 8114(h)) to the founding depth agreed on (clause 8106).
The unit of measurement shall be the metre of prefabricated pile installed. That part of the
prefabricated pile projecting above the average ground surface shall not be measured and paid for.
Irrespective of the total length of pile installed, the quantity installed within each depth range shall be
The tendered rates shall include full compensation for hoisting and driving the pile.
Item 81.21 Extra over item 81.17, irrespective of the depth, to form augered and bored pile
holes through identified obstructions consisting of:
(a) Coarse gravel with a matrix content of less than x% (maximum percentage to be indicated)
............................................................................................................................... metre (m)
(b) Boulders (description of and maximum size indicated) ........................................ .metre (m)
(c) Rock formation (description and class of rock indicated)............... ....................... metre (m)

The unit of measurement shall be the metre of pile hole formed through the identified obstruction,
measured from the depth at which the identified obstruction is encountered to the depth at which
normal auger drilling or boring can be resumed; or another type of identified obstruction is
encountered.
The tendered rates shall include full compensation for all additional work and incidentals required for
forming the pile hole through the identified obstruction.
Notes:
Sub Pay item 81.21(a): The matrix content indicated shall be the percentage by volume of matrix in
material containing coarse gravel. Where the maximum percentage indicated is exceeded, payment
for forming holes through such material shall be made under item 81.17. Unless otherwise specified,
the maximum percentage of matrix shall be accepted to be 60%.
Where obstructions other than those provided for in Pay item 81.21 can be identified, they shall be
described on the drawings and/or in the Particular Specifications. Provision therefore shall be made in
the Bill of Quantities under extensions to Pay item 81.21.
Item 81.22 Forming augered and bored pile holes through unidentified obstructions
(b) Percentage allowed for overhead and profit on item 81.22 (a) ..........................Percent (%)
A provisional sum is allowed in the Bill of Quantities for covering the cost of this work.
Payment for the work authorised by the Engineer shall be in accordance with the provisions of the
General Conditions of Contract.
Item 81.23 Driving temporary casings for driven displacement piling systems or installing
prefabricated piles through identified or unidentified obstructions
(b) Percentage allowed for overhead and profit on item 81.22 (a) ..........................Percent (%)
A provisional sum is allowed in the Bill of Quantities for covering the cost of this work.
The method of payment for the work authorised by the Engineer shall be in accordance with the
provisions of the General Conditions of Contract.
Item 81.24 Extra over items 81.17, 81.18 and 81.20 for raking piles:
(a) Holes for piles of (diameter and rake indicated) .................................................. . metre (m)
(b) Temporary casing for driven displacement pile systems (diameter and rake indicated) .......
............................................................................................................................... metre (m)
(c) Prefabricated piles (type, size and rate Indicated) ................................................ metre (m)
The tender rates shall include full compensation for all additional work and incidentals for forming the
pile bores or for driving and later extracting the temporary casing, or for installing prefabricated piles to
the rake shown.
Item 81.25 Forming under-reams for piles ............................................................. number (No)

The unit of measurement shall be the number of pile holes (diameter indicated) under-reamed.
The tendered rate shall include full compensation for all work to be done in forming the under-reams.

Item 81.26 Forming the bulbous bases for piles ................................................... number (No)
The unit of measurement shall be the number (No) of bulbous bases formed (diameter indicated).
The tendered rate shall include full compensation for all work to be done in forming the bulbous bases
but shall exclude the concrete work.
Item 81.27 Socketing piles into rock formation ..................................................... number (No)
The unit of measurement shall be the number of (No) sockets (class of rock and length of socket
indicated), the length of which shall be not less than the specified length, formed in rock, the hardness
of which shall be not less than that of the specified class of rock.
The tendered rate shall include full compensation for all work to be done for socketing into the rock
formation.
Item 81.28 Installing and removing temporary casings in augered holes for piles metre (m)
The unit of measurement shall be the meter (m) of temporary casing installed (diameter indicated) as
directed by the Engineer or shown on the Drawings. Only the installed temporary casing below the
average ground surface (sub-clause 8114(h)) shall be measured for payment.
The tendered rate shall include full compensation for supplying, installing and removing the temporary
casings.
Item 81.29 Installing permanent pile casing for piles ................................................. metre (m)
The unit of measurement shall be the metre (m) of permanent casing installed (diameter indicated) as
instructed by the Engineer or shown on the Drawings.
The tendered rate shall include full compensation for supplying and installing permanent pile casings.
Item 81.30 Steel reinforcement in cast in situ piles:

(a) Mild-steel bars .................................................................................................... .....tonne (t)
(b) High-yield stress-steel bars (type indicated) ............................................................tonne (t)
The unit of measurement for steel bars shall be the tonne of reinforcement in place in accordance with
the Drawings or as authorised.
Ties and other steel used for keeping the reinforcing steel in position shall be measured as steel
reinforcing under the appropriate Sub-item.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding,
trial welds, placing and fixing the steel reinforcing, including all tying wires, spacers and waste.
Item 81.31 Cast in situ concrete in piles, under reams, bulbous bases and sockets ..............
........................................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of concrete placed in the cast-in-situ piles; under-
reams; bulbous bases; and sockets.
3
Item 81.32 Extra over item 81.31 for concrete cast under water .................... cubic metre(m )
The unit of measurement shall be the cubic meter of concrete cast under water, the quantity being
calculated as for pay item 81.31.
The tendered rate shall include full compensation for all additional work, incidentals and extra cement
required for placing the concrete under water.

Item 81.33 Splicing/coupling prefabricated piles for lengthening ....................... number (No)
The unit of measurement shall be the number (No) of splices/couplings in prefabricated piles (size of
pile indicated) for each size of pile.
The tendered rate shall include full compensation for all work required for splicing/coupling the piles in
accordance with the specifications.
Item 81.34 Stripping/cutting the pile heads ............................................................. number(No)

The unit of measurement shall be the number (No) of heads of each type and diameter/size of pile
stripped/cut (type and diameter/size of pile indicated).
The tendered rate shall include full compensation for providing all tools and stripping/cuffing the pile
heads.
Item 81.35 Establishment on the site of the load testing of piles ............................ lump sum
The tendered lump sum shall include full compensation for the establishment on the site and
subsequently removing all the special plant and equipment required for conducting the load tests on
piles. This cost does not vary with the number of load tests to be conducted.
Payment for this work shall be made by way of a lump sum, 100% of which shall be paid after the
testing assembly has been completely assembled and the first load test has been started.
Item 81.36 Load tests on piles ................................................................................ number (No)

The unit of measurement shall be (compression/tension test, diameter/size, specified working load
indicated) the number (No) of load tests conducted on the instruction of the Engineer, for each
specified working load.
Test piles, but not anchor piles and anchors, shall be measured as specified above for permanent
piles. Anchor piles and anchors shall be deemed to form part of the testing equipment under this item.
The tendered rate shall include full compensation for installing the anchor piles and anchors where
necessary; conducting load tests, and processing and submitting the results.
Item 81.37 Establishment on the site for core drilling ............................................... lump sum
The tendered lump sum shall include full compensation for the establishment on the site and
subsequently removing all the equipment required for conducting the core drilling. This cost does not
vary with the quantity of work to be done.
This work will be paid for by way of a lump sum, 100% of which will become payable when the
equipment has been set up at the first location and drilling has started.
Item 81.38 Moving the equipment to and assembling it at each location where cores are to be
drilled ...................................................................................................... number (No)
The unit of measurement shall be the number (No) of locations to which the core-drilling equipment is
to be moved and at which it has to be assembled.
The tendered rate shall include full compensation for the cost of moving and assembling the
equipment.

Item 81.39 Drilling the cores (Diameter indicated) in:

(a) Concrete ................................................................................................................... metre (m)
(b) Founding formation:
(i) Irrespective of hardness ....................................................... ……………….metre (m)
(ii) With a hardness of (hardness indicated) .............................. ……………….metre (m)
The unit of measurement shall be the metre of hole drilled. The tendered rate shall include full
compensation for drilling; recovering and packing the cores; keeping the drilling records; providing
core boxes; providing and installing the casings; and backfilling the holes with grout.
Item 81.40 Standing time for pile-installation frame ..................................................... hour (h)
The unit of measurement for the standing time of a pile installation frame shall be the hours during
which the pile installation frame is standing in terms of Sub-clause 8114(x).
The tendered rate shall include full compensation for all fixed costs for the pile-installation frame,
which is not connected with its operation and the quantity of work done.
Item 81.41 Establishment on the site for constructing the caisson ........................ lump sum
The tendered lump sum shall include full compensation for the establishment on the site and later
removing all special plant and equipment necessary for constructing the caissons. This cost shall not
vary in accordance with the number of caissons constructed.
This work will be paid for by way of a lump sum, 50% of which will be paid when all the equipment is
on the site and the first caisson has been constructed. The second payment of 25% of the lump sum
will be paid after half the number of caissons has been completed, and the final payment of 25% after
all the caissons have been completed and the equipment has been removed from the site.
Item 81.42 Formwork for caissons ................................................................. square metre (m²)

2
The unit of measurement shall be the square meter (m ) of formwork (class of finish indicated); and
only the area of formwork in contact with the finished face of the concrete shall be measured.
Formwork for construction joints shall be measured for payment under class F1 surface finish but shall
be measured only for construction joints shown on the Drawings or as prescribed by the Engineer.
The tendered rate shall include full compensation for supplying all the materials; erecting the false
work and formwork; constructing the forms; forming the grooves, fillets, chamfers, stop ends for
construction joints; treating the forms; all accessories; and stripping and removing the formwork after
completion of the work. Payment for formwork shall be made only after the formwork has been
stripped and the surface finish approved.
Item 81.43 Steel reinforcement for caissons:

(a) Mild-steel bars ..........................................................................................................tonne (t)
(b) High-yield-stress-steel bars (type indicated) ............................................................tonne (t)
the Drawings or as may have been authorised.
Ties and other steel used for positioning the reinforcing steel shall be measured as steel reinforcing
under the appropriate sub-item.
The tendered rates shall include full compensation for supplying; delivering; cutting; bending; welding;
trial welding joints; placing; and fixing the steel, including all tying wire, spacers and waste.

3
Item 81.44 Cast in situ concrete in caissons and concrete seals ..................... cubic metre (m )
The unit of measurement for cast in situ concrete shall be the cubic metre of concrete in place (class
of concrete indicated).
Concrete quantities in the caissons shall be calculated from the dimensions shown on the Drawings or
authorised by the Engineer, and the length of the caisson from the founding level to the specified cut-
off level. The quantity of concrete in the concrete seal shall be calculated in accordance with the
dimensions shown on the Drawings or authorised by the Engineer.
The tendered rate shall include full compensation for procuring and furnishing all the materials, storing
the material, providing all plant, mixing, transporting, placing and compacting the concrete, all sealing,
curing the concrete and repairing defective concrete. Payment shall distinguish between the different
classes of concrete.
Item 81.45 Cutting edge for caissons ..........................................................................number (No)

The unit of measurement shall be (diameter/size indicated) the number of caissons provided with
cutting edges, irrespective of the material they have been constructed of.
The tendered rate shall include full compensation for manufacturing, supplying, delivering and
installing the complete cutting edge as well as for joining the cutting edge to the caisson unit. Where
the cutting edge is of concrete and forms part of the bottom element, the tendered rate shall include
full compensation for all additional work required for completing the element.
Item 81.46 Sinking caissons through material situated

Within the following successive depth ranges (diameter/size indicated):
(a) Om up to 5m .......................................................................................................... metre (m)
(b) Exceeding 5 m and up to 10 m .............................................................................. metre (m)
(c) etc in increments of 5 m depths ............................................................................. metre (m)
The limits of the successive depth ranges shall be measured down from the firm horizontal base (sub-
clause 8114(h)) to the agreed founding level (clause 8106).
The unit of measurement shall be the metre of caisson sunk. Irrespective of the length of caisson
sunk, the quantity for each depth range shall be measured and paid for separately.
The tendered rates shall include full compensation for locating and holding in position, dewatering,
pumping, kentledge and lubricating the sides of the caisson, and for all work in connection with the
sinking of the caisson which is not paid for elsewhere.
Item 81.47 Excavation for caissons:

(a) Excavating soft material situated within the following successive depth ranges:
3
(i) 0m up to 2m. .............................................................. ……………..cubic metre (m )
3
(ii) Exceeding 2 m and up to 4 m ................................... ……………..cubic metre (m )
3
(iii) etc in increments of 2 m depths ................................. ……………..cubic metre (m )
(b) Extra over sub-pay item 81.47(a) for excavation in hard material irrespective of depth .......
3
.................................................................................................................... cubic metre (m )
The limits for the successive depth ranges shall be measured down from the firm horizontal base
(Sub-clause 8114(h)) to the excavated level inside the caisson.

The unit of measurement shall be the cubic metre of material, measured in the original position before
excavation. The quantity of excavation for each depth range shall be calculated from the gross area of
the caisson in plan and the depth of excavation completed within each depth range.
Irrespective of the total depth of excavation, the quantity of material within each depth range shall be
The tendered rates shall include full compensation for excavation in the classified material, spoiling or
stockpiling the material, hauling the excavated material, trimming the bottom of the excavation,
dewatering, pumping and removing the material leaking into the caisson before sealing.
Item 81.48 Filling the caissons

The unit of measurement shall be the cubic metre of sand placed above the concrete seal in the
caisson compartments.
The tendered rate shall include full compensation for supplying and placing the sand; transporting the
material; and compacting the material as specified.
Item 81.49 Stripping the caisson heads

The unit of measurement shall be the number of caissons (size of caisson indicated) of each size
stripped.
The tendered rate shall include full compensation for cutting away, trimming and disposing of the
concrete removed.

Division 8200 Falsework, Formwork, and Concrete Finishes
8201 Scope
This Division covers the design; material specifications; supply; and erection of all falsework and
formwork.
This Division also covers the specification for the classes of concrete surface finishes on formed and
unformed concrete surfaces.
8202 Dimensions
The dimensions shall be in accordance with the details shown on the Drawings or as instructed by the
Engineer.
8203 Material Requirements for Falsework and Formwork
(a) Falsework
Falsework shall consist of either purpose-made; or proprietary timber; or metal, props, beams,
bracings or ties; adequate to support the forces imposed during construction of the concrete structure
without excessive deflection.
All props shall be provided with suitable base plates to distribute the superimposed loads. The props
shall also be adjustable to support the beams to the level required by the design.
(b) Formwork
Formwork shall be provided to produce hardened concrete to the lines, levels and shapes shown on
the Drawings or specified elsewhere. It shall have adequate strength to carry all applied loads,
including the pressure of fresh concrete, vibration loads, weight of workers and equipment, without
loss of shape.
Forms shall be mortar tight and designed to allow removal without risk of damage to the completed
structure.
Joints in the formwork shall be perpendicular to the main axis of the shape of the concrete.
Design of formwork for high sections shall be such that it shall not be necessary to drop concrete
freely from a height greater than 1.6m or to move concrete along the formwork after deposition.
Material used for formwork shall be sound and suitable for the purpose intended and surface finish
specified.
Provision shall be made for the accurate location and firm support of fittings, bolts, anchorages and
formers of holes as shown on the Drawings. Temporary fittings used for the support of the formwork
shall be arranged to permit removal without damage to the concrete.
The use of wires and or bolts extending to the surface of the concrete shall not be permitted except
where shown on the Drawings.
Forms for edges of concrete shall be filleted and, for re-entrant angles, chamfered as shown on the
Drawings.
Formwork shall consist of purpose-made or proprietary timber; metal or plastic boarding; or sheeting;
adequate to support the forces during construction of the concrete structure without excessive
deflection. The following are recommended formworks.

(i) Tongue-and-groove boarding

The boarding shall be of suitably dried timber, which will not warp, distort or cause discolouration of
the concrete. The widths of the boards shall be as specified on the Drawings or in the Bill of Quantities
or as prescribed by the Engineer. Boards shall be supplied in lengths not shorter than 3 m.
(ii) Steel forms to exposed surfaces

For classes F2 and F3 surface finish the individual panels shall be assembled sufficiently rigidly and
so clamped as not to deform or kick during handling or under the pressure of the wet concrete. The
surfaces of the forms, which are to be in contact with the concrete, shall be clean, free from deposits
or adhering matter, ridges or spatter, which will impart irregularities and blemishes to the concrete
surface and shall also be free from indentations and warps.
(iii) Void formers

When used in permanent work, void formers shall be subject to the approval of the Engineer. Where
void formers of a special design are required, details thereof will be specified. Void formers shall be
manufactured from material which will not leak, tear or be damaged during the course of construction
and shall be of such tight construction so as to prevent undue loss of the mortar component of the
concrete through leakage. The units shall be sufficiently rigid so as not to deform during handling; or
under the pressure of the wet concrete.
For mild-steel spiral-lock-formed void formers, the metal thickness shall be as follows, unless
otherwise specified:
 Un-braced void formers

o 0.6 mm for diameters of up to 600 mm;
o 0.8 mm for diameters exceeding 600 mm and up to 800 mm;
o 1.0 mm for diameters exceeding 800 mm and up to 1 000 mm.
 Braced void formers
o 0.6 mm for diameters of up to 800 mm;
o 0.8 mm for diameters exceeding 800 mm and up to 1 000 mm;
o 1.0 mm for diameters exceeding 1,000 mm and up to 1 200 mm;
o 1.2 mm for diameters exceeding 1 200 mm.
The thickness specified for braced void formers shall apply to formers internally braced with timber or
equivalent braces. The braces shall be at spacings not exceeding 2.0 m and not further than 1.0 m
from the end of each unit. Timber cross braces shall consist of members with cross-sectional
dimensions of at least 50 mm x 50 mm.
All hollow void-former units shall be provided with a 12 mm diameter drainage hole at each end.
(iv) Chamfer and recess fillets

Timber fillets used for forming chamfers and recesses on exposed surfaces shall be made from new
material unless otherwise authorised.
(v) Jack rods for sliding formwork

The jack rods, base plates and couplers shall be strong enough to carry the design load under all
operating conditions without buckling, distorting or causing damage to the concrete. Jack rods which
are to remain permanently embedded in the concrete shall comply with the requirements for storing
and surface condition of steel reinforcement. Under no circumstances shall bent rods be used in the
work.
The jack rods used shall have a diameter of at least 25mm.

8204 Design and Construction Requirements
(a) Drawings
When complete details for forms and falsework are not shown on the Drawings, the Contractor shall
prepare and submit drawings according to Clause 1212 of these specifications. The Contractor shall:
 Design and show the details for constructing safe and adequate forms and falsework that
provide the necessary rigidity, support the loads imposed, and produce in the finished
structure the required lines and grades.
 Show the maximum applied structural load on the foundation material.
 Include a drainage plan or description of how foundations will be protected from saturation,
erosion, and/or scour.
 Precisely describe all proposed material.
 Describe the material that is not describable by standard nomenclature (such as AASHTO or
ASTM specifications) based on manufacturer's tests and recommended working loads.
 Evaluate falsework material and ascertain whether the physical properties and condition of the
material is such that it can support the loads assumed in the design.
 Furnish design calculations and material specifications showing that the proposed system will
support the imposed concrete pressures and other loads.
 Provide an outline of the proposed concrete placement operation listing the equipment, labour,
and procedures to be used for the duration of each operation.
 Include proposed placement rates and design pressures for each pour.
 Include a superstructure placing diagram showing the concrete placing sequence and
construction joint locations.
 Provide design calculations for proposed bridge falsework. A registered professional Engineer
proficient in structural design shall design, sign, and seal the drawings. The falsework design
calculations shall show the stresses and deflections in load supporting members.
 Show anticipated total settlements of falsework and forms. Include falsework footing
settlement and joint take-up. Design for anticipated settlements not to exceed 25 mm.
 Design and detail falsework supporting deck slabs and overhangs on girder bridges so there is
no differential settlement between the girders and the deck forms during placement of deck
concrete.
 Design and construct the falsework to elevations that include anticipated settlement during
concrete placement and required camber to compensate for member deflections during
construction.
 Show the support systems for form panels supporting concrete deck slabs and overhangs on
girder bridges.
 Show details for strengthening and protecting falsework over or adjacent to roadways and
railroads during each phase of erection and removal.
 Include intended steel erection procedures with calculations in sufficient detail to substantiate
that the girder geometry will be correct.
 Submit details of proposed anchorage and ties for void forms.
 Submit separate falsework drawings for each structure, except for identical structures with
identical falsework design and details, with the layout, safety provisions and calculations

included. Construction of any unit of falsework shall not be started until the drawings for that
unit have been submitted, reviewed and accepted by the Engineer.
 Make provision for access arrangements for inspection purposes.
(b) Design
(i) General
The Contractor's design and drawings of the falsework and formwork shall comply amongst others
with all statutory requirements. The design shall also include safety provisions as required by the
Engineer.
The Engineer may require the Contractor to submit the design and drawings of the falsework and
formwork for any structure for consideration and approval.
The Contractor shall submit his design criteria and calculations and detail drawings of the falsework
and formwork to the Engineer at least fourteen (14) days before the Engineer's approval is required.
(ii) Falsework
The Contractor shall make his own assessment of the allowable bearing pressure on the foundation
material and shall design the footings and falsework to prevent overloading, differential settlement and
unacceptable overall settlement.
In assessing the allowable bearing pressure, due account shall be taken of the effect of wetting on the
foundation material.
In designing the falsework, cognizance shall also be taken of the redistribution of load which may
occur on account of the effect of temperature, wind force, the pre-stressing of curved and skewed
structures, stage construction, flooding and debris.
Particular attention shall be given to providing transverse and diagonal bracing as well as rib-stiffeners
on cross-bearers.
(iii) Formwork
Formwork shall be so designed as to be sufficiently rigid to ensure that the specified dimensional
tolerances can be achieved under the combined action of self-weight, dead load and imposed loads
as well as the additional loads resulting from the rate of concreting, the layer thickness of the concrete
cast in one operation and the method of placing and compaction.
(iv) Sliding formwork

The Contractor shall be responsible for the design of the sliding formwork. Prior to fabrication or
bringing the sliding formwork and any additional equipment to the site, the Contractor shall submit
drawings of the complete sliding- formwork assembly to the Engineer for approval.
The drawings shall show full details of the forms, jacking frames, access ladders, hanging platforms,
safety rails and curing skirts as well as details of the jacks and jack layouts.
The Contractor shall be required to submit to the Engineer, before slide casting commences, an
instruction manual in which the sliding techniques, jacking procedure, methods of keeping the
formwork level, the procedure to be adopted to prevent bonding of the concrete to the forms and a
method for releasing the forms in the event of bonding, the instrumentation and monitoring of the slide
casting and correcting for verticality, twisting and levelness are described in detail.
The formwork panels shall be inclined to give a small taper, the forms being slightly wider at the
bottom than at the top.
The taper shall be so designed as to produce the specified concrete thickness at the mid-lift level of
the form.

The spacing of the jacks with their jack rods shall be so designed that the dead load of the sliding-
formwork assembly, the frictional load; and the mass of materials, personnel and equipment will be
evenly distributed and within the design capacity of the jacks used.
(c) Construction
(i) General
Notwithstanding approval given by the Engineer for the design and drawings prepared by the
Contractor for the falsework and formwork, and the acceptance of the falsework and formwork as
constructed, the Contractor shall be solely responsible for the safety and adequacy of the falsework
and formwork; and shall indemnify (and keep indemnified) the Employer and the Engineer against any
losses, claims or damage to persons or property whatsoever which may arise out of or in
consequence of the design, construction, use and maintenance of the falsework and formwork and
against all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in
respect thereof or in relation thereto.
For works on, over, under or adjacent to any railway line which is controlled by a statutory authority,
the Contractor shall comply, inter alia, with the requirements for the preparation and submission of
Drawings for falsework and formwork, and the submission of certificates for the proper construction
thereof, all in accordance with the official specifications of such authority.
After having constructed the falsework and formwork; and prior to placing the reinforcing steel and/or
the concrete; the Contractor shall inspect the falsework and formwork. Dimensions shall be checked,
unevenness of surfaces shall be corrected; and special attention paid to the adequacy and tightness
of all bolts, ties and bracings, as well as to the soundness of the foundations.
The Contractor shall give the Engineer at least 24-hours’ notice of his intention to place the concrete to
enable the Engineer to inspect all aspects of the completed work. However, before notifying the
Engineer, the Contractor shall satisfy himself that the work complies in all respects with the
specifications.
Concrete sections with dimension of smaller than 200 mm shall not be formed with sliding formwork
unless authorised by the Engineer.
Where no provision has been made in the Bill of Quantities for sliding formwork, the Contractor may, in
a covering letter to the tender, submit a lump sum which reflects a saving in the cost for the use of
sliding formwork in lieu of conventional formwork.
(ii) Falsework
Falsework shall be erected in accordance with the approved drawings incorporating such
modifications as required by the Engineer.
The Contractor shall take precautions to prevent deterioration of the foundations during the course of
construction.
The falsework shall incorporate features, which will permit adjustment to the alignment of the formwork
to neutralise the expected settlement and deflection under load.
(iii) Formwork
The formwork for bridge decks shall be erected to levels calculated from the information given on the
plans for roadworks and bridges.
The levels shall be adapted to make provision for the specified pre-camber as well as for the expected
deflection and settlement of the fully loaded falsework and formwork. The levels shall be set out and
checked at intervals not exceeding 2.5 m.

For constructing the formwork, the Contractor may, subject to the provisions of Clause 8203 of this
Division, use any material suitable for, and compatible with, the class of surface finish and dimensional
tolerances specified for the particular member.
Formwork shall be sufficiently rigid to maintain the forms in their correct position, shape and profile
and shall be of such tight construction that the concrete can be placed and compacted without undue
loss or leakage of the mortar component of the concrete.
The joints between contiguous formwork elements shall be of a tight fit and, where necessary, the
joints shall be caulked, taped or packed with a sealing gasket, all at no extra payment if undue
leakage occurs or can be expected. Paper, cloth or similar material shall not be used for this purpose.
The formwork construction shall permit accurate erection and easy stripping without shock,
disturbance or damage to the cast concrete. Where necessary, the formwork assembly shall permit
the removal or release of side-forms independently of the soffit forms.
Metal supports, ties, hangers and accessories embedded in the concrete shall be removed to a depth
of not less than the cover specified for the reinforcement. No wire ties shall be used.
All external corners shall be chamfered by fillet strips being fixed into the corners of the formwork to
form 25 mm x 25 mm chamfers. Re-entrant angles need not be chamfered unless specified.
Where polystyrene or similar material susceptible to damage is used, it shall be lined with a hard
surface on the side to be concreted. The hard material shall be sufficiently resilient to ensure that the
required quality of work can be achieved.
Where it is specified, all formwork ties shall be provided with recoverable truncated cones between
sleeve ends and formwork faces to ensure that sleeve ends are not exposed on concrete surfaces.
The cones shall have a minimum depth of 15 mm.
(iv) Formwork to exposed surfaces

The formwork and boards shall be so arranged as to form a uniform and regular pattern in line with
and perpendicular to the main axis of the member, unless otherwise approved or directed by the
Engineer.
Joints between contiguous members shall, after caulking, taping or sealing, be treated to prevent
blemishes, stains and undue marks from being imparted to the concrete surface.
Bolt and tie positions shall be so arranged that they conform to the symmetry of the formwork panels
or boards. Bolt and rivet heads which will be in contact with the formed surface shall be of the
countersunk type and shall be treated to prevent marks from forming on the concrete surface.
The formwork at construction joints shall be braced to prevent steps from forming in the concrete
surfaces at the joints between successive stages of construction. Where moulding or recess strips are
specified, they shall be neatly butted or mitred.
(v) Formwork for open joints

The requirements for formwork for open joints shall, unless otherwise specified, apply only to cases
where the distance between opposite concrete surfaces is equal to or less than 150 mm.
Formwork for open joints shall be constructed to produce a class F1 surface finish to concealed
surfaces or a class F2 or F3 surface finish corresponding to the in-plane surface finish of the bordering
concrete surfaces as defined in Clause 8205. The material used and the construction of the formwork
shall permit its complete removal to form the open joint.
No solvent shall be used to remove formwork unless approved by the Engineer.

(vi) Openings and wall chases

Openings and wall chases shall be provided only where indicated on the Drawings or as authorised by
the Engineer.
Frames for openings shall be rigid and firmly secured in position to prevent their moving. Temporary
holes shall be so formed that they will not create an irregular pattern in relation to the rest of the
exposed formed concrete surface.
(vii) Sliding formwork

Unless otherwise specified in the Particular Specifications, hoisting equipment for sliding formwork,
which operates stepwise with upward movements of between 10 mm and 100 mm will be acceptable.
However, the use of linked hydraulic or pneumatic jacks which are reversible and driven by an
electrically operated pump; and which can hoist at a steady rate, is preferable. The jacks shall have
independent controls for regulating verticality and levelness. The jacking system shall ensure that the
sliding- formwork assembly can be hoisted evenly.
The use of hoisting systems, which operate without jack rods, shall be subject to the approval of the
Engineer.
All equipment shall be thoroughly tested and inspected before installation and shall be maintained in a
good working order throughout the entire sliding operation.
The Contractor shall keep adequate back-up plant, equipment and quantities of materials on the site
to ensure that the slide casting can proceed without interruption.
 Instrumentation and monitoring

The Contractor shall supply and install suitable instrumentation on the sliding platform and foundations
and against the sides of the structure for monitoring the height, verticality, levelness and twisting at
regular distances. The equipment used, its utilisation and the frequency of recording any readings,
shall be approved by the Engineer.
The Contractor shall be responsible for all monitoring work and shall ensure that records of all
readings and measurements taken are filed systematically and are at all times available to the
Engineer and the person in control of the sliding operation.
Unless otherwise specified, the verticality of the structure shall be controlled with laser alignment
apparatus or optical plummets, and the levelness of the sliding forms with a water-level system with
reference control points placed at strategic locations.
Height and verticality shall be monitored at intervals not exceeding four (4) hours. The readings shall
be plotted immediately on graphs. When the structure is more than 10 mm out of vertical, the Engineer
shall be notified immediately.
 Supervision
During the entire period of the sliding operation, a competent person who is fully acquainted with the
sliding technique and the Contractor's methods of construction shall be in attendance on the sliding
platform and in control of the sliding operations.
 Construction
The jacking frame shall be constructed with adequate clearance between the underside of the cross
members and top of the formwork to allow the horizontal reinforcement and embedded items to be
correctly installed.

A control procedure shall be agreed on by the Contractor and the Engineer to ensure that all the
reinforcement is placed. At all times there shall be horizontal reinforcement above the level of the top
of the formwork panel.
Guides shall be provided to ensure that the vertical reinforcement can be correctly placed and the
specified concrete cover over the reinforcement maintained.
Where the jack rods are to be recovered, adequate precautions shall be taken in respect of their
removal without damage being caused to the concrete.
Where jack rods occur at openings or wall chases, adequate lateral support shall be provided to
prevent their buckling.
Equipment and material shall be so distributed on the working platforms that the load will be evenly
distributed over the jacks.
Guard plates shall be provided at the tops of the forms to the outside walls to prevent the concrete
from falling down the outside.
The framework, forms and platforms shall be regularly cleared and the accumulation thereon of
redundant concrete prevented.
The Contractor shall take all precautions to prevent contamination of the concrete by leaking oil or
other causes.
 The sliding process

The Contractor shall give the Engineer 24 hours’ notice of his intention to commence with slide
casting.
Permission to commence with the sliding shall not be given by the Engineer before the sliding-
formwork assembly is fully operative and the complete stock of all materials required for the slide
casting as well as back-up plant and equipment are on the site.
The Contractor shall ensure that the rate of sliding is such that the concrete at the bottom of the
formwork has obtained sufficient strength to support itself and all loads which may be placed on the
concrete at the time; and that the concrete does not adhere to the sides of the forms.
The slide-casting operation shall be continuous, without any interruptions, until the full height of the
structure has been reached, and shall be geared and organised so as to maintain an average rate of
sliding of 350 mm per hour.
 Interruptions
When the sliding operations are delayed for more than 45 minutes, the Contractor shall prevent
adhesion of the setting concrete to the formwork panels by easing the forms or moving them slightly
every 10 minutes; or alternatively, where reversible jacks are used, by lowering the forms by 10 mm to
25 mm.
Wherever interruptions occur, emergency construction joints shall be formed and treated in
accordance with Division 8400 of these specifications. Before concreting is restarted, the form shall be
adjusted to fit snugly onto the hardened concrete so as to prevent steps from being formed on the
exposed concrete surface.
When slide casting is recommenced, care shall be taken to prevent the fresh concrete from being lifted
off from the old concrete.

(viii) Permanent formwork

Void formers shall be secured in position at regular intervals to prevent displacement and distortion
during concreting. The void formers shall be supported on precast concrete blocks or rigid welded
steel cradles, all subject to approval by the Engineer.
The ties securing the void formers shall be attached to the formwork and cross bearers of the
falsework. The void formers shall not be tied to or supported on the reinforcement.
Permanent formwork to deck soffits such as corrugated metal or precast concrete panels may be used
if shown in the contract documents or approved by the Engineer. Prior to the use of such forms, the
Contractor shall provide a complete set of details to the Engineer for review and approval. Unless
otherwise noted, the Drawings for the structures shall be dimensioned for the use of removable forms.
Any changes necessary to accommodate stay-in-place forms, if approved, shall be at the expense of
the Contractor
(ix) Preparing the formwork

The surfaces of forms which are to be in contact with fresh (wet) concrete shall be treated to ensure
non-adhesion of the concrete to the forms and easy release from the concrete during the stripping of
the formwork.
Release agents shall be applied strictly in accordance with the manufacturer's instructions, and every
precaution shall be taken to avoid the contamination of the reinforcement, pre-stressing tendons and
anchorages. In the selection of release agents, due regard shall be given to the necessity for
maintaining a uniform colour and appearance on the exposed concrete surfaces.
Before the concrete is placed, all dirt and foreign matter shall be removed from the forms and the
forms shall be thoroughly wetted with water.
(d) Removal of forms and falsework

Falsework and formwork shall not be removed before the concrete has attained sufficient strength to
support its own mass and any loads, which may be imposed on it. This condition shall be assumed to
require the formwork to remain in place after the concrete has been placed, for the appropriate
minimum period of time given in Table 8204/1.
Forms that do not support the dead load of concrete members and forms for railings and barriers may
be removed 24 hours after the concrete is placed.
Falsework and formwork shall be carefully removed without exposing the cast concrete to damage,
disturbance or shock.
Weather may be regarded as being "normal" when atmospheric temperatures adjacent to the
concrete, as measured by a maximum-and-minimum thermometer, do not fall below 15°C, and as
"cold" when temperatures, similarly measured, fall below 5°C. When the minimum temperatures fall
between these values, the length of the period after which the formwork may be removed shall be
determined by interpolation between the periods specified for normal and cold weather.
Any period during which the temperature remains below 2°C shall be disregarded in calculating the
minimum time which shall elapse before the forms are removed.

Table 8204/1: Minimum Form/Support Release Criteria
Minimum
Per cent of Specified
Number of Days
Structural Element 28-Day Strength
Since
(%)
Last Pour
(a) Columns and wall faces (not yet supporting loads) 50 3
(b) Mass piers and mass abutments (not yet
50 3
supporting loads) except pier caps
(c) Box Girders 80 21
(d) Simple span girders, T-beam girders, slab bridges,
cross beams, caps, pier caps not continuously
80 21
supported, struts, and top slabs of concrete box
culverts.
(e) Trestle slabs where supported on wood stringers 70 10
(f) Slabs and overhangs where supported on steel
70 10
stringers or pre-stressed concrete girders
(g) Pier caps continuously supported 60 7
(h) Arches, continuous span bridges, rigid frames 90 21
For continuously reinforced concrete structures the falsework and supporting formwork shall not be
removed before the concrete of the last pour has reached the appropriate minimum age given in
Table 8204/1 or the appropriate minimum strength. Where the structure is constructed in stages, the
falsework and supporting formwork shall be removed as specified or authorised by the Engineer.
On pre-stressed-concrete structures the falsework and supporting formwork shall be removed after the
full pre-stressing force relating to the particular stage of construction has been applied, unless
otherwise specified or authorised.
Falsework supporting the deck of rigid frame structures, excluding box culverts, shall not be removed,
until backfill material is placed and compacted against the vertical legs of the frame.
8205 Formed Surfaces: Classes of Finish
(a) General
In addition to complying with the tolerances specified in Division 81100 of these specifications, the
surface finish on formed concrete surfaces shall also comply with the requirements of this Clause.
(b) Class F1 surface finish

After repair work has been done to surface defects in accordance with sub-clause 8206(b), no further
treatment of the as-stripped finish will be required. This finish is required on permanently concealed
formed surfaces.
(c) Class F2 surface finish

This finish shall be equivalent to that obtained from the use of square-edged timber panels and boards
wrought to the correct thickness, or shutter boards or steel forms arranged in a regular pattern. This
finish is intended to be left, as struck but surface defects shall be remedied in accordance with sub-
clause 8206(b). Although minor surface blemishes and slight discolouration will be permitted, large
blemishes and severe stains and discolouration shall be repaired where so directed by the Engineer.
Forms for permanently exposed concrete surfaces shall be lined with plywood, masonite or other such
material as approved by the Engineer. The form liner material shall be free form wrinkles, warping,
open joints and other surface imperfections at the time of pouring.

(d) Class F3 surface finish

This finish shall be that obtained by first producing a class F2 surface finish with joint marks which
form an approved regular pattern to fit in with the appearance of the structure. All projections shall then
be removed, irregularities repaired and the surface rubbed or treated to form a smooth finish of
uniform texture, appearance and colour. This surface finish is required on all permanently exposed
formed surfaces unless a class F2 finish is specified.
Unless specified to the contrary, steel forms may be used to form surfaces with a class F3 surface
finish.
(e) Board surface finish

This finish shall be that obtained by using tongue-and-groove timber boarding arranged in an
approved regular pattern.
The finish is intended to be left as struck but surface defects shall be remedied in accordance with
sub-clause 8206 (b) and large fins trimmed where directed by the Engineer.
(f) Protecting the surfaces

The Contractor shall ensure that permanently exposed concrete surfaces are protected from rust
marks, spillage and stains of all kinds and other damage during construction.
8206 Remedial Treatment of Formed Surfaces
(a) General
The surfaces shall be inspected by the Engineer immediately after the formwork has been removed
and agreement shall be reached with the Engineer regarding any remedial treatment that may be
required. The remedial treatment shall be carried out without delay. No surfaces may be treated before
inspection by the Engineer.
(b) Repairs to surface defects

Surface defects such as small areas of honeycombing, cavities produced by form ties, large isolated
blow-holes, broken corner edges, etc. shall be repaired with mortar having a cement and sand ratio
equal to that of the concrete being repaired.
For the repair of large or deep areas of honeycombing and defects, special approved methods and
techniques, such as pneumatically applied mortar, pressure grouting and epoxy bonding agents may
be used on approval of the Engineer.
Where, in the opinion of the Engineer, the extent of the honeycombing or defects is of such a degree
that doubt exists about the effectiveness of repair work, the Contractor shall, at his own cost, perform
a load test to prove that the structural safety of the repaired member has not been prejudiced, failing
which, the structure shall be rebuilt in part or in full at the Contractor's cost.
Where the concrete has been damaged by adhesion to the formwork panel, the cracked and loose
concrete shall be removed; or where the fresh concrete has lifted off at construction joints, the crack
shall be scraped out immediately on both sides of the wall to a depth of at least 50 mm. The cavities
so formed shall then be repaired as described herein.

(c) Rubbing the surfaces

If the finish of exposed formed surfaces does not comply with the requirements for uniformity of
texture, appearance and colour, the Contractor shall, when so instructed by the Engineer, rub down
the exposed surfaces of the entire structure or of any part of it as specified herein.
The surface shall be saturated with water for at least one (1) hour. Initial rubbing shall be done with a
medium-coarse carborundum stone, where a small amount of mortar, having a sand:cement ratio
equal to that of the concrete being repaired, is used on the surface. Rubbing shall be continued until
all form marks, projections and irregularities have been removed and a uniform surface has been
obtained. The paste produced by the rubbing shall be left in place. The final rubbing shall be carried
out with a fine carborundum stone and water. This rubbing shall continue until the entire surface is of a
smooth, even texture and is uniform in colour. The surface shall then be washed with a brush to
remove surplus paste and powder.
Where the concrete surfaces formed by sliding formwork require treatment to achieve the surface
finish specified for the member, the concrete shall, as soon as the surfaces under the formwork are
exposed, be floated with rubber-lined floats to the desired finish.
8207 Unformed Surfaces: Classes of Finish
(a) Class U1 surface finish (rough)

This surface finish is required on those portions of bridge decks or culvert decks which are to receive
asphalt or concrete surfacing or which are to be covered by backfilling material.
Where the placing and compacting of the concrete have been completed as specified in with Division
8400 of these specifications, the top surface shall be screeded off with a template to the required
cross-section and tamped with a tamping board to compact the surface thoroughly and to bring mortar
to the surface, so as to leave the surface slightly rough but generally at the required elevation.
(b) Class U2 surface finish (floated)

This surface finish is required on footways; the tops of wing walls and retaining walls; exposed
concrete shoulders and unsurfaced areas on bridge decks; the inverts of box culverts; and decks
which are to receive surfacing other than asphalt or concrete.
The surface shall first be given a class U1 surface finish and after the concrete has hardened
sufficiently, it shall be wood-floated to a uniform surface free from trowel marks. For non-skid surfaces
such as on footways and bridge decks, the surface shall then be given a broom finish. The
corrugations so produced shall be approximately 1mm deep, uniform of appearance and width and
shall be perpendicular to the centreline of the pavement.
(c) Class U3 surface finish (smoothly finished)

This surface finish shall be required at bearing areas and the tops of concrete railings.
The surface shall first be given a class U1 surface finish, and after the concrete has hardened
sufficiently, it shall be floated with a steel float to a smooth surface to within the dimensional tolerances
specified in with Division 81100 of these specifications.
Rubbing with carborundum stone after the concrete has hardened shall be allowed but under no
circumstances will plastering of the surface be permitted.


Item 82.01 Formwork for indicated class of finish ........................................ square metre (m²)
The unit of measurement shall be the square metre (class of finish indicated as F1, F2, F3 or board)
surface finish to (description of member to which applicable).
Item 82.02 Vertical formwork for indicated class of finish ........................... square metre (m²)
Item 82.03 Horizontal formwork for indicated class of finish ...................... square metre (m²)
Item 82.04 Inclined formwork for indicated class of finish ............................. square metre (m²)
The unit of measurement shall be the square metre, and only the actual area of formwork in contact
with the finished face of the concrete shall be measured. Formwork for the different classes of finish
shall be measured separately. Formwork for construction joints shall be measured for payment under
class F1 surface finish, but only formwork for mandatory construction joints shall be measured for
payment.
The tendered rates shall include full compensation for procuring and furnishing all materials required;
erecting the falsework and formwork; constructing the forms; forming the grooves, fillets, chamfers and
stop-ends for construction joints; treating and preparing the forms; all bolts, nuts, ties, struts and stays;
stripping and removing the formwork after completion of the work; all labour, equipment and
incidentals; and rubbing and surface treatment. Payment of 80% of the amount due for formwork will
be made when the formwork has been removed, and payment of the remaining 20% will be made on
approval of the concrete surface finish.
Item 82.05 Permanent formwork

(a) To form voids of (diameter size of void indicated), in (description of member to which
applicable) ................................................................................................ square metre (m²)
(b) Of (description of material and member to which applicable) ................. square metre (m²)
The unit of measurement shall be the square metre of concrete area formed with permanent formwork.
The tendered rates shall include full compensation for procuring and furnishing all the materials
required; installing the formwork; and labour, equipment and incidentals.
Item 82.06 Formwork to form open joints ......................................................... square metre (m²)
(description of member to which applicable, and location)
The unit of measurement shall be the square metre of concrete area formed.
Surfaces formed prior to the construction of the final surface for completing the joint, shall be
measured under Pay Items 82.01, 82.02, 82.03 or 82.04, as may be applicable.
The tendered rate shall include full compensation for procuring and furnishing all the materials
required, constructing the formwork and subsequently removing all the material within the joint space,
as well as labour, equipment and incidentals. Payment for formwork to open joints shall be made only

after the forms and filler material have been completely removed and approval of the surface finish
has been obtained.
Item 82.07 Establishment on the site for sliding formwork operations .................. lump sum
The unit of measurement is tendered in lump sum, shall include full compensation for the
establishment on the site and the subsequent removal of the complete sliding-formwork assembly,
special plant and equipment, and incidentals for the sliding work, the cost of which does not vary with
the actual amount of sliding work done.
This work will be paid for by way of a lump sum, 75% of which will become payable when the sliding-
formwork assembly, plant and equipment have been fully installed at the first structural member on the
site, and the remaining 25% will become payable after all sliding work has been completed and the
said items have been removed from the site.
Item 82.08 Transporting to and setting up the sliding formwork assembly ....... number (No)
(description of each structure)
The unit of measurement shall be the number of structures to which the complete sliding-formwork
assembly has to be transported and set up in position ready to be commissioned.
The tendered rate shall include full compensation for all costs involved in dismantling, transporting and
erecting of the complete sliding-formwork assembly.
Item 82.09 Forming the concrete by sliding formwork for structures ...................... metre (m)
(for description of each structure and class of surface finish to exposed surfaces indicated)
The quantity measured shall be the actual height in metres of each structure formed by the sliding
technique.
The tendered rate shall include full compensation for sliding; instrumentation and monitoring; the
maintenance of the complete sliding-formwork assembly; plant and equipment; supplying, installing
and recovering the jack rods; floating, repairing and treating the concrete surfaces; forming the
emergency construction joints; and all labour, equipment and incidentals.

Division 8300: Steel Reinforcement for Structures
8301 Scope
This Division covers the furnishing and placing of steel reinforcement in concrete structures.
8302 Materials Requirement
(a) Steel reinforcement

Deformed and plain carbon steel reinforcing bars shall conform to the requirements of AASHTO M-31
and ASTM A615.
Low alloy steel, deformed and plain billet steel bars, for concrete reinforcement shall be Grade 60 to
ASTM A 706. The nominal area of the bar, as given in Table 1 of AASHTO M-31 or ASTM A 706, shall
be used for computation.
Steel fabric reinforcement shall comply with AASHTO M-225, M-221 or M-54 as appropriate.
Hard drawn mild steel wire reinforcement shall comply with AASHTO M-55, welded steel wire fabric for
concrete reinforcement.
Deformed steel wire for concrete reinforcement shall comply with AASHTO M-225 and cold drawn
steel wire for concrete reinforcement shall comply with AASHTO M-32.
(b) Mass of Reinforcing Bars

The mass of Reinforcing Bars is shown in the Table 8302/1. The Contractor shall provide the
manufacturer's chart for the exact calculations.
Table 8302/1: Mass of Reinforcing Bars (as recommended by the South African Reinforced
Concrete Association)
Bar Diameter (mm) Mass (kg/m)

8 0.395
10 0.617
12 0.888
16 1.58
20 2.47
25 3.85
32 6.31
40 9.86
(c) Mechanical couplers

Mechanical couplers shall be used only if pre-approved or detailed in the contract documents or
authorised in writing by the Engineer. Such mechanical splices shall develop in tension or
compression, as required, at least 125% of the specified yield strength of the bar being spliced.
When requested by the Engineer, up to two field couplers out of each 100, or portion thereof, placed in
the work and chosen at random by the Engineer, shall be removed by the Contractor and tested by the
Engineer for compliance to the required 125% of the specified yield strength of the bars being spliced
(d) Supply and Storage of Materials

Steel reinforcement shall only be used from a source with prior approval of the Engineer.

Steel reinforcement shall be stacked off the ground and, in aggressive environments, protection shall
be provided in the form of sheds or tarpaulins. All reinforcement shall be rust free and the Engineer
shall be entitled to reject on inspection any reinforcement showing signs of rusting.
Different grades of reinforcement shall be stored in separate locations and shall be clearly identified
and logged. Steel delivered directly to site shall also be logged accordingly by the Contractor.
Details of each consignment showing source of supply; manufacturer’s certificate of test strength;
constituents (% carbon etc); and date of rolling shall be submitted to the Engineer. However, this will
not relieve the Contractor of any responsibility for testing the material as instructed by the Engineer.
(a) Equipment
The equipment used for the cutting, cropping and bending of the reinforcement shall be capable of
producing prefabricated or in-situ assemblies complying with the requirements of this Division.
(b) Bending of Reinforcement

Reinforcement shall be cut and bent to the dimensions shown on the Drawings and in accordance with
ACI 315.
All reinforcement shall be bent at temperatures in the range of 5ºC to 100ºC unless otherwise
The Contractor shall submit a Bar Bending Schedule at least thirty (30) days prior to the placement of
the reinforcement, for the Engineer's approval. All costs for the preparation of the schedule shall be
incidental to the work.
No flame cutting of steel bars shall be permitted except with the approval of the Engineer.
Except as otherwise approved, all bars shall be bent cold and bending shall be done slowly, a steady,
even pressure being used without jerk or impact.
If approved, hot bending of bars of at least 32 mm diameter will be permitted, provided that the bars do
not depend for their strength on cold working.
When hot bending is approved, the bars shall be heated slowly to a cherry red heat (not above 840ºC)
and after bending shall be allowed to cool slowly in air. Quenching with water shall not be permitted.
Reinforcing bars that have already been bent shall not be re-bent at the location of the original bend
without the permission of the Engineer.
(c) Surface Conditions

Immediately before the concrete is placed around the reinforcement, the reinforcement shall be clean,
free from mud, oil, grease, paint, loose rust, loose mill scale or any other substance that can have an
adverse chemical effect on the steel or concrete, or reduce the bond.
(d) Placing and Fixing

Reinforcement shall be secured against displacement during the placement and compaction of the
concrete.
Reinforcement shall be positioned as shown on the Drawings and accurately secured in these
positions within the tolerance given in Division 81100 of these specifications by tying with wire or by
the use of suitable clips or, where permitted by the Engineer, by tack welding. The wire adjacent to
permanently exposed faces and the internal faces of hollow box superstructures shall be 1.2 mm
diameter stainless steel. Elsewhere 1.6 mm diameter soft annealed wire may be used.
Cover and spacer blocks required to support the reinforcement shall be as small as possible
consistent with their use and be of approved design and material.
Projecting ends of ties or clips shall not encroach into the concrete cover.
Where protruding bars are exposed to the elements for an indefinite period the bars shall be
adequately protected against corrosion and damage and shall be properly cleaned before being
permanently encased in concrete.
In members that are formed with sliding formwork, spacer "ladders" for the placing and fixing of the
wall reinforcement shall be used at spacings indicated on the Drawings or as directed by the Engineer.
The ladders shall consist of two 3.7 m long bars with lateral ties of 4 mm diameter welded to them in
the form of a ladder. The ties shall be spaced at multiples of horizontal bar spacing in the wall, and be
used to secure the horizontal reinforcement. The laps in the horizontal reinforcement shall be
staggered to ensure that no part of two laps in any four consecutive layers lie in the same vertical
plane.
(e) Cover
The term "cover" in this context shall mean the minimum clear thickness of concrete between the
surface of the reinforcement and face of the concrete.
The cover to any bar in an outer layer of reinforcement shall not be less than the minimum cover
shown on the Drawings and shall not exceed the minimum by more than 4% of the overall dimension
of the member, measured in the same direction, or by more than 20 mm, whichever is the lesser.
Where no cover is indicated, the minimum cover provided shall not be less than the appropriate values
shown in Table 8303/1.
The cover shall be increased by the expected depth of any surface treatment (eg when concrete is
bush-hammered or when rebates are provided).
Additional cover as directed by the Engineer shall be provided if porous aggregates are used.
Concrete spacer blocks shall be made with 5 mm maximum size aggregate and shall be of the same
strength and material source as the surrounding concrete. Tying wire complying with the requirements
of this clause shall be cast into the block for the purpose of tying it to the reinforcement. The blocks
shall be formed in specially manufactured moulds and the concrete compacted in a table vibrator all to
the approval of the Engineer.
Cover blocks or spacers required for ensuring that the specified cover is obtained shall be of a
material, shape, and design acceptable to the Engineer.
The Contractor shall provide adequate support to reinforcement by way of stools/chairs. The
stools/chairs shall be suitably robust, and fixed securely so that they cannot swivel or move. The
stools/chairs shall have sufficient strength to perform the required functions, taking into account
amongst others temporary loads such as the weight of workmen and wet concrete, and forces caused
by vibrators and other methods of compacting the concrete.

Table 8303/1: Minimum concrete cover over reinforcement
Water/Cement Ratio 0.40 0.4 to 0.5 ≥0.50

SITUATION COVER (mm) COVER (mm) COVER (mm)
Direct exposure to salt water 80 100 120
Cast against earth (i.e. Bottom of footings) 60 75 90
Exterior other than above 40 50 60
Interior other than Up to 35 Bar 32 40 48
above (i.e. hollow
structures) 45 and 55Bars 40 50 60
Bottom of cast-in- Up to 35 Bar 35 35 42

place slabs 45 and 55Bars 40 50 60
Precast soffit form panels 20 20 24
Precast Reinforced Non-corrosive environments 32 40 48
Piles Corrosive environments 60 75 90
Precast Pre-stressed Piles 40 50 60
Non-corrosive environments 40 50 60
Corrosive environments 60 75 90
General Protected 60 75 90
Cast-in-place Piles
Shells 40 50 60
Auger cast, tremie concrete or
60 75 90
slurry construction
(f) Laps and Joints

Laps, joints, splices and mechanical couplings shall be made only by the methods specified and at the
positions shown on the Drawings, refer to ACI 318 or as agreed to by the Engineer.
(g) Welding
Welding of reinforcement shall only be carried out where shown on the Drawings or agreed to by the
Engineer. Refer to ACI 318.
Flash butt welding shall only be carried out with the combination of flashing, heating, upsetting and
annealing to the Engineer's approval and only those machines that automatically control this cycle of
operations shall be used.
Metal-arc welding of reinforcement shall be carried out in accordance with ANSI/AWS D1.4 Structural
Welding Code, Reinforcing Steel and the recommendations of the reinforcement manufacturers
subject to the approval of the Engineer and the satisfactory performance of trial joints.
Other methods of welding (eg resistance welding) may be used subject to the approval of the Engineer
and to their satisfactory performance of trial joints.
Welded joints shall be full strength welds and their strength shall be assessed by tests to destruction
on samples selected by the Engineer.

Item 83.01 Steel reinforcement for structure

(a) Steel bars (Size, Type, Class and Grade indicated) ................................................tonne (t)
(b) Welded steel fabric (Type indicated) ................................................................ kilogram (kg)

the Drawings or as authorised by the Engineer.
The unit of measurement for welded steel fabric shall be the kilogram of fabric reinforcement in place
and the quantity shall be calculated from the net area covered by the mesh, excluding laps.
The tendered rate shall include full compensation for the supply, delivery, cutting, bending, welding,
placing and fixing of the steel reinforcement; including all tying wire, clips, separators, stools/chairs
and other steel used for positioning reinforcement; extra reinforcement at laps; and all wastage.
Item 83.02 Mechanical couplers for (diameter of bar indicated) ......................... Number (No)
The unit of measurement shall be the number of mechanical couplers for each bar diameter installed.
The tendered rate shall include full compensation for the supply of all material; for preparing and
modifying the bar ends to be joined; as well as for all tools; equipment and labour required to complete
the work.
Item 83.03 Spacer "ladders" ............................................................................................ tonne (t)

The pay item for Spacer "ladders" shall be the tonne of steel in place in accordance with the Drawings
or as authorised by the Engineer.
The tendered rate shall include full compensation for the supply, delivery, cutting, bending, welding,
placing and fixing of the "ladders"; including all tying wire, spacers, stools/chairs, supports and
wastage.

Division 8400: Concrete for Structures
8401 Scope
This Division covers the manufacture, transport, placing, curing and testing of concrete used in the
Works where plain, reinforced, or pre-stressed concrete is specified.
8402 Materials
(a) Cement
Cement used for structures shall be either ordinary Portland or sulphate resisting cement complying
with the requirements of AASHTO M-85 or blended hydraulic cement complying with the requirements
of AASHTO M-240 or Pozzolana cement manufactured within Ethiopia.
(b) Admixtures
Acceptance of chemical admixtures shall be based on the manufacturer’s Certificate of Compliance. If
required by the Engineer, admixtures shall be sampled and tested before they are used.
Admixtures, if allowed, shall comply with the following:
(i) Air-Entraining Admixtures

Air-Entraining Admixtures shall comply with AASHTO M 154.
(ii) Type A Water-Reducing Admixtures

Type A Water-Reducing Admixtures shall conform to the requirements of AASHTOM 194 Type A.
(iii) Type B Retarding Admixtures

Type B Retarding Admixtures shall conform to the requirements of AASHTO M 194Type B.
(iv) Type C Accelerating Admixtures

Type C Accelerating Admixtures shall conform to the requirements of AASHTO M194 Type C and only
non-chloride accelerating admixtures shall be used.
(v) Type D Water-Reducing and Retarding Admixtures

Type D Water-Reducing and Retarding Admixtures shall conform to the requirements of
AASHTO M194 Type D.
(vi) Type E Water-Reducing and Accelerating Admixtures

Type E Water-Reducing and Accelerating Admixtures shall conform to the requirements of AASHTO M
194 Type E and only non-chloride accelerating admixtures shall be used.
(vii) Type F Water-Reducing, High Range Admixtures

Type F Water-Reducing, High Range Admixtures shall conform to the requirements of AASHTO M194
Type F.
(viii) Type G Water-Reducing, High Range, and Retarding Admixtures

Type G Water-Reducing, High Range, and Retarding Admixtures shall conform to the requirements of
AASHTO M194 Type G.
(c) Aggregates
Aggregates, which are to be used in the Works, shall have negligible alkaline reactivity. When tested in
accordance with ASTM C 227, the mean mortar bar expansion values at 3 and 6 months shall be less
than +0.5% and +0.10% respectively.
When tested in accordance with ASTM 289, the aggregate shall be proven to be non-reactive.
If all of the significant rock components meet the requirements of this sub-clause, aggregate for
structures shall be considered to be unsusceptible to alkali aggregate reaction.

A significant rock component is defined as one, which forms, more than 4% by weight of the coarse or
fine aggregate.
The Contractor shall provide the Engineer with petrographic details of the significant rock components
contained in the aggregates.
Any aggregate containing the mineral opal shall be considered susceptible to alkali aggregate
reaction. A qualified Geologist shall carry out the identification of rock and its placing in the appropriate
group.
Aggregates shall not contain deleterious amounts of organic materials such as grass, timber or similar
materials as shown in Table 8402/1.
Table 8402/1: Maximum amount of deleterious substances

Maximum
Percentage by Mass
Item
Fine Coarse
Aggregate Aggregate
Material passing 0.075 mm sieve 2.0 1.0
Lightweight material 2.0 2.0
Organic matter 0 0
Clay lumps 1.0 0.5
Other deleterious substances 2.0 1.0
The sum of the percentage of all deleterious substances in the aggregate delivered to the mixer, shall
not exceed 3% for fine aggregate and 2% for coarse aggregate. If there is a potential danger of alkali
aggregate reaction the Engineer’s decision as to the suitability of the aggregate shall be final and
binding.
(i) Fine Aggregate for Portland Cement Concrete.

Fine aggregate shall consist of natural sand, manufactured sand, or a combination of natural and
manufactured sand conforming to AASHTO M-6 Class B including the reactive aggregate
supplementary requirement, except as amended or supplemented by the following:
 Material passing a 0.075 mm sieve shall not exceed 3.0% when tested in accordance with
AASHTO T-11.
 The Sand Equivalent Value in accordance with AASHTO T-176 shall not be more than 75.
 Lightweight fine aggregate shall conform to AASHTO M-195.
The fine aggregate grading shall comply with Table 8402/2
Table 8402/2: Grading of Fine Aggregate
Sieve size Percentage of total mass

(mm) passing sieve
10 100
4.76 95-100
2.38 68 - 86
1.19 47 - 65
0.59 27 - 42
0.30 9 - 20
0.15 0-7
0.075 0 - 2.5 (4.0)*
*Note: subject to approval by the Engineer.

(ii) Coarse Aggregate for Portland Cement Concrete.

Coarse aggregate shall conform to AASHTO M-80 Class A, except as amended or supplemented by
the following:
 The Los Angeles Abrasion value shall not exceed 40% when determined in accordance with
the requirements of AASHTO T-96.
 The adherent coating value shall not exceed 1.0% when determined in accordance with the
requirements of FLH T-512.
 For bridge decks or surface courses, aggregates known to polish, or carbonate aggregates
containing less than 25% by mass of insoluble residue as determined by ASTM D 3042, shall
not be used.
 Lightweight coarse aggregate shall conform to AASHTO M-195.
The coarse aggregate grading shall comply with Table 8402/3
Table 8402/3: Nominal Size and Grading of Coarse Aggregate

Percentage of total mass passing sieve
Nominal
Sieve size (mm)
Size (mm)
31.25 25 19 12.5 10 4.75 0.075
25 90 - 100 - 0 – 20 0-2 - 0 - 0.5
20 100 80 – 100 - 10 - 40 0-4 0 - 0.5
10 100 90 - 100 40 - 70 0 - 15 0 - 0.5
(d) Water
Water shall be clean and free from detrimental concentration of acids, alkalis, urine, salts, sugar, and
other organic or chemical substances.
If the water used is not obtained from a public drinking water main the Engineer may require the
Contractor to have the suitability of the water proved by tests carried out by an approved laboratory.
Such tests shall comply with the requirements of AASHTO T-26 and in particular:
 The total percentage of solids by weight shall not exceed 2.25%.
For reinforced concrete construction the requirements are:
 Chloride (as Cl2) (ASTM D 512) 400 ppm max.

 Sulphates (as SO3) (ASTM D 516) 500 ppm max.
 Alkali Carbonates and Bicabonates 750 ppm max
 Total dissolved solid (ASTM D 1888) 2000 ppm max.
 pH 7 to 9
Concrete made with water not meeting the requirements specified herein may be rejected for inclusion
in the Works.
8403 Storage of Materials
(a) Cement
Cement, which is stored on site, shall be kept under cover, that provides adequate protection against
moisture and other factors which may promote deterioration.
When the cement is supplied in bags, they shall be closely and neatly stacked to a height not
exceeding twelve (12) bags and arranged so that they can be used in the order in which they were
delivered to the Site.

Storage of cement in bulk in silos or similar containers shall be permitted provided that the cement
drawn for use is measured by mass and not by volume.
Cement shall not be kept in storage for longer than six (6) weeks without the Engineer's permission
and different brands and/or types of the same brand shall be stored separately. Any cement in storage
which in the opinion of the Engineer is no longer satisfactory for whatever reason shall be rejected and
disposed of as directed by the Engineer.
The Contractor shall provide the Engineer with copies of all bills of loading for each consignment of
cement within three (3) days of its delivery to site and advise the Engineer of, but not limited to, the
following:
 The source of the cement;

 The tonnage, type and date on which the consignment is received;
 The location where the cement is being stored.
The Contractor shall maintain a stock book inventory of all cement on site indicating the date of arrival;
storage location; distribution to and use at the various sites within the project; and the tonnage of each
type of cement available in storage.
The following shall also apply:
 Only cement from a source and of a type approved by the Engineer shall be used;
 The delivery of all consignments at the site or to storage shall be logged with information as
indicated previously to the Engineer;
 The test certificate from the supplier/manufacturer shall be submitted to the Engineer.
However, this will not relieve the Contractor from testing the material as instructed by the
Engineer;
 The Engineer shall be entitled to reject any lot or thereof on account of improper storage or
the initiation of setting of the cement in any bag prior to its use.
(b) Aggregates
Aggregates of different nominal sizes shall be stored separately and in such a way that segregation is
avoided. Intermixing of different materials and contamination by foreign matter shall be avoided.
Aggregates exposed to a marine environment shall be covered to protect them from salt
contamination.
Where concrete is batched on site, the aggregates shall be stored in bins with a 3.0 m wide concrete
apron slab constructed around the outer edge of the aggregated stockpile area to prevent
contamination during the process of tippling and hoisting the aggregate. The aggregates shall be
tipped on the concrete apron slab. The storage bin shall have a concrete floor of 150 mm thickness.
(c) Storage Capacity

The storage capacity provided and the amount of material stored (whether cement, aggregates, or
water) shall be sufficient to ensure that no interruptions to the progress of the work are occasioned by
lack of materials.
Special storage facility shall be provided for storing cement to ensure that cement does not get
exposed to moisture.

(d) Deteriorated Material

Material that has deteriorated, or that has been contaminated or otherwise damaged, shall not be
used in concrete. Such materials shall be removed from the site without delay.
8404 Concrete for Structures
(a) Concrete Grade and Class

The Grade and/or Class of concrete used for structures shall be as described in the Contract.
For each Grade of concrete the specified minimum 28-day cube and cylinder compressive strength in
MPa shall be as given in Table 8404/1.
The Class of concrete shall be defined by its Grade followed by the maximum size of aggregate.
Table 8404/1: Grade of Concrete for Structures
Minimum 28 days Compressive Strength

Grade (MPa)
Cube Cylinder
25 25.0 20
30 30.0 24
40 40.0 32
50 50.0 40
60 60.0 48
(b) Minimum Cement Content

The minimum cement content shall be that which is required to ensure compliance with the minimum
strength requirement in Table 8404/1.
(c) Maximum Water/Cement Ratio

The ratio of the weight of free water to the weight of cement in the mix shall not exceed 0.5 unless
otherwise permitted by the Engineer.
(d) Maximum Cement Content

3
The cement content shall not exceed 550 kg/m unless otherwise described in the Contract or agreed
by the Engineer.
(e) Design of Concrete Mixes for Structures

Unless otherwise specified, concrete mixes for structures shall be designed in accordance with an
internationally approved method as approved by the Engineer.
Prior to the design of the mix the Contractor shall notify the Engineer of the nature and source of each
of the constituent materials that he proposes to use.
The water content shall be the minimum required to provide the workability necessary for the placing
and compaction of the concrete as determined by trial mixes.
The 7 to 28 day strength relationship shall be established during the mix design procedure by making
6 pairs of cubes and testing of one from each pair to be tested at seven days and the other at 28 days.
The workability of the concrete shall be determined by the Contractor and shall be the optimum
required for the proper placing and full compaction of the concrete around the reinforcement, tendons
and ducts and completely fills the formwork.

The workability of the fresh concrete shall be determined by the slump test in accordance with the
(f) Prescribed Mix

When a "prescribed mix" is specified, the Engineer will specify the mix proportions and the Contractor,
or the manufacturer, shall undertake to provide properly mixed concrete containing the constituents in
the specified proportions in accordance with the following:
 The Contractor shall be responsible for supplying the constituent materials for the concrete,
and shall, at least two (2) months before the start of any concrete work on the Site, supply to
the Engineer samples of each aggregate for testing purposes.
 If the materials comply with the Specification, the Contractor shall supply further samples of
sizes indicated by the Engineer, for determination of the mix proportions for each class of
concrete.
 The class of concrete is indicated by the characteristic 28-day cube crushing strength in MPa
and the maximum size of the coarse aggregate in the mix (eg Grade 30/20 concrete means
concrete with the characteristic cube compressive strength of 30 MPa and cylinder
compressive strength of 24 MPa at 28 days and a maximum size of coarse aggregate of
20 mm). The classes of concrete for prescribed mixes shall be specified in the particular
specifications. For each class the following shall be specified:
o The estimated minimum cube compressive strength in MPa at 28 days.
o The maximum nominal size of coarse aggregate in mm; and its proportion in the mix.
o The proportion of the fine aggregate in the mix.
o The type and proportion of cement in the mix.
o The water:cement ratio.
o The slump in mm.
 The Engineer shall have the right to vary, as the work proceeds, the proportions of the
constituents of the concrete. Payment for variations shall be made at the tendered rates as
specified in the Particular Specifications.
 The nominal mix ratio shall be determined on site through mix design and testing to comply
with the concrete grade requirements.
(a) Storage and Handling of Material

In addition to the provisions of Clause 8403, the following requirements for storage and handling
presented in this sub-clause shall apply during construction:
 All material shall be stored and handled in a manner that prevents segregation, contamination,
or other harmful effects.
 Aggregate shall be stored and handled in a manner that ensures uniform moisture content at
the time of batching.
 Different cements and pozzolana shall be stored in separate silos. Alternatively these
materials may be stored in bags under dry weather-proof covers on raised floors and each
consignment shall be kept separate and distinct.
Any cement that has become injuriously affected by damp or other causes shall be removed
from the Site immediately. No cement shall be stored on Site for longer than six (6) weeks.
 Aggregates shall be stored on site in different single sizes of coarse and fine aggregate which
shall be kept separate from each other.
 All aggregates shall be kept free from contact with deleterious matter with adequate provision
for drainage, and shall be stored and handled so as to avoid segregation.
 All materials shall be delivered and stored in such a way as to ensure that they can be used in
the same order in which they are delivered.
 Fine aggregate shall be deposited at the site of mixing for at least eight (8) hours before use.
(b) Measuring Material
(i) Cement
Where cement is supplied in standard bags, the bags shall be assumed to contain 50 kg. All cement
taken from bulk storage containers and from partially used bags shall be batched by mass, to an
accuracy of within 3%.
(ii) Water
Mixing water for each batch shall be measured, either by mass or by volume to an accuracy of within
3%.
(iii) Aggregates
All aggregates shall be measured separately by mass, except as otherwise provided in this Clause, to
an accuracy of within 3%.
Separate fine and coarse aggregates shall be used except for classes 7, 10, and 15 where all-in
aggregate may be used.
Aggregates for prescribed mix concrete as specified in sub-clause 8404(f), may be measured
separately by volume.
Batching boxes for volume batching shall be filled without tamping, ramming, or consolidation of any
kind (other than that occurring naturally during the filling process), and shall be screeded off level with
their topmost edges.
Any adjustment of the volume shall be made by supplementary containers of a suitable size.
Adjustments by the incomplete filling of batching boxes to marks on their inside faces shall not be
permitted.
Fine aggregate shall be tested for bulking at the beginning of and half-way through each concreting
shift; and adjustment shall be made to the batch volume to give the true volume required.
The measurement of cement in gauge boxes will not be permitted and volume batching shall be
planned to use whole bags of cement.
(iv) Admixtures
Any solid admixtures to be added shall be measured by mass. Liquid or paste admixtures may be
measured by volume or mass. The quantity shall be measured to an accuracy of within 5%.
(v) Adjustment to Mix Proportions

During production, adjustments of mix proportions may be made in order to minimise the variability of
strength and to approach more closely the target mean strength. Such adjustments are regarded as
part of the proper control of production but the specified limits of minimum cement content and
maximum water/cement ratio shall be maintained. Changes in cement content shall be declared. Such
adjustments to mix proportions shall not be taken to imply any change to the current margin.
(c) Batching Plant, Mixers, and Agitators

The batching plant, mixer, and agitator shall conform to AASHTO M-157.

Continuous volumetric mixing equipment shall conform to AASHTO M-241.
(d) Mixing
The concrete shall be mixed in a central mix plant or in a truck mixer.
All equipment shall be operated within the manufacturer's recommended capacity.
The produced concrete shall be of uniform consistency.
Under no circumstance shall hand-mixing be allowed unless approved by the Engineer.
(i) Central-Mix Plant

Liquid admixtures shall be dispensed through a controlled flow-meter.
Dispensers shall have sufficient capacity to measure, at one time, the full quantity of admixture
required for each batch.
If more than one admixture is used, each admixture shall be dispensed with separate equipment.
The coarse aggregate, one-third of the water, and all air entraining admixtures shall be charged into
the mixer first, following which, the remaining material shall be added.
The batch shall be mixed for at least 50 seconds. The mixing time shall be counted after all cement
and aggregate are in the drum.
The contents of an individual mixer shall be removed before a succeeding batch is charged into the
drum.
(ii) Truck Mixer

Concrete shall be mixed in a truck mixer capable of combining the ingredients of the concrete within
the specified number of mixing revolutions into a thoroughly mixed and uniform mass. It shall also be
capable of discharging the concrete uniformly.
The volume of mixed concrete permitted in the drum of truck mixers shall not exceed the
manufacturer's rating on the capacity plate. Agitators shall similarly be capable of producing concrete
with a satisfactory degree of uniformity.
Mixers with any section of the blades worn by 25 mm or more below the original manufactured height
shall not be used.
Mixers and agitators with accumulated hard concrete or mortar in the mixing drum shall not be used.
Admixtures shall be added to the mix water before or during mixing.
The batch shall be charged into the drum so a portion of the mixing water enters in advance of the
cement.
Each batch of concrete shall be mixed not less than 70 and not more than 100 revolutions of the drum
or blades at the mixing speed. The count of mixing revolutions shall begin as soon as all materials,
including water, are placed in the mixer drum.
(e) Delivery
Concrete shall be produced and delivered to permit a continuous placement with no concrete
achieving initial set before the remaining concrete being placed adjacent to it.
The methods used for delivering, handling, and placing shall minimise re-handling of the concrete and
prevent any damage to the structure.
Concrete that has developed an initial set shall not be used.

Concrete shall not be re-tempered by adding water.
(i) Truck mixer/agitator

When a truck mixer or truck agitator is used to transport concrete that is completely mixed in a
stationary central construction mixer, mixing during transportation shall be done as per the
manufacturer's recommended agitating speed.
Water and admixtures (if in the approved mix design) may be added at the work site to obtain the
required slump or air content, provided that, the total of all water in the mix does not exceed the
maximum water/cement ratio and the concrete has not obtained an initial set. If additional water is
necessary, water shall be added only once and shall be re-mixed with thirty (30) revolutions at mixing
speed. The re-mixing shall be completed within 45 minutes after the initial introduction of mixing water
to cement or cement to aggregates.
(ii) Non-Agitating Equipment

Non-agitating equipment may be used to deliver concrete if the concrete discharge is completed within
20 minutes from the beginning of the addition of the cement to the mixing drum.
The equipment used shall have smooth, mortar tight, metal containers capable of discharging the
concrete at a controlled rate without segregation. Covers shall be provided when needed for
protection.
(f) Batching and Mixing
(i) General
Unless otherwise permitted by the Engineer, concrete shall be mixed on the Site.
The quantities of cement, fine aggregate and the various sizes of coarse aggregate shall be measured
by weight unless otherwise agreed by the Engineer. Alternatively, cementitious materials may be
measured by using a whole number of bags in each mix.
The quantity of water required to be added to the mix shall be measured by volume or weight. Any
admixture to be added to the mix shall be measured by volume or weight and, if solid, shall be
measured by weight.
Different types of cement shall not be mixed.
The batch weight of aggregate shall be adjusted to allow for the free moisture content of the aggregate
being used.
All constituent materials shall be thoroughly mixed and any admixtures uniformly distributed
throughout the batch.
Following the addition of water, the concrete shall be mixed for at least the minimum time
recommended by the manufacturer of the mixing plant prior to discharge from the mixer.
Mixers that have been out of use for more than 30 minutes shall be thoroughly cleaned before any
fresh concrete is mixed. Mixing plants shall be thoroughly cleaned before changing from one type of
cement to another.
An experienced operator shall conduct mixing of materials for concrete.
Unless otherwise approved, mixing shall be carried out in a mechanical batch mixer of approved type
and capable of producing a uniform distribution of ingredients through the batch.
(ii) Charging the Mixer

The Engineer shall approve the sequence of charging and, unless otherwise instructed, the same
sequence shall be maintained.

The volume of the mixed material per batch shall not exceed the manufacturers rated capacity of the
mixer.
(iii) Mixing and Discharge

The period of mixing shall be measured from the time when all materials are in the drum until the
commencement of discharge.
The mixing period shall be 90 seconds and may only be reduced if, on the basis of site tests, the
Engineer is satisfied that the reduced mixing time will produce concrete having essentially the same
strength and uniformity as concrete mixed for 90 seconds.
The reduced mixing time shall, however, not be less than 50 seconds or the manufacturers
recommended mixing time, whichever is the greater. A suitable timing device shall be attached to the
mixer to ensure that the maximum mixing time is complied with.
The first batch to be run when starting with a clean mixer, shall contain only 2/3 of the required amount
of coarse aggregate to facilitate "coating" of the mixer drum.
Discharge shall be so carried out that there is no segregation of the materials in the mix. The mixer
shall be emptied completely before it is recharged.
(iv) Maintenance and Cleaning of the Mixer

If the mixer has stopped running for any period in excess of 30 minutes, it shall be thoroughly cleaned
out, particular attention being paid to the removal of any build-up of materials in the drum, in the
loader, and around the blades or paddles. Worn or bent blades and paddles shall be replaced.
Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all hardened
concrete shall be removed.
(v) Standby Mixer

When casting sections where it is important that casting should continue without interruption a standby
mixer shall be held in readiness to run on 15 minutes’ notice in case of breakdown of the stock mixer.
(vi) Ready Mixed Concrete

Ready mixed concrete as defined in AASHTO M-157 batched off the site may be used only with the
agreement of the Engineer and shall comply with all requirements of the contract.
The concrete shall be carried in purpose-made agitators, operating continuously, or truck mixers. The
concrete shall be compacted and in its final position within two (2) hours of the introduction of cement
to the aggregates, unless a longer time is agreed by the Engineer. The time of such introduction shall
be recorded on the delivery note, together with the weight of the constituents of each mix.
When truck mixed concrete is used, water shall be added under supervision, either at the site or at the
central batching plant, as agreed by the Engineer but in no circumstances shall water be added in
transit.
Unless otherwise agreed by the Engineer, truck mixer units and their mixing and discharge
performance shall comply with the requirements of AASHTO M-157. Mixing shall continue for the
number and rate of revolutions recommended in accordance with AASHTO M-157 or, in the absence
of the manufacturer’s instructions, mixing shall continue for not less than 100 revolutions at a rate of
not less than 7 revolutions per minute.
(g) Trial Mixes

At least 60 days prior to commencing concrete work the Contractor shall carry out laboratory trials of
designed mixes with the materials from all sources to be used in the Works including all admixtures.

Trial mixes shall be made in the presence of the Engineer or his representative and shall be subject to
the approval of the Engineer.
Trial mixes shall be repeated if necessary until the proportions that will produce a concrete which
complies in all respects with this specification have been determined.
The proportions determined as a result of the laboratory trial mixes may be adjusted if necessary
during the construction of the trial length. Thereafter, neither the materials nor the mix proportions
shall be varied in any way except with the written approval of the Engineer.
Any change in sources of materials or mix proportions that are proposed by the Contractor during the
course of the works shall be assessed by making new laboratory trial mixes except that the Engineer
may approve minor alterations to the mix.
(h) Compressive Strength

Concrete shall be accepted based on conformance to the requirement for the specified compressive
strength at 28 days for sub-lots as tested and determined by the Engineer.
A sub-lot shall be defined as the material represented by an individual strength test which should be
50 cubic metres or less. An individual strength test is the average compressive strength of cylinders or
cubes from the same sample of material. Each sub-lot shall be deemed to have met the specified
compressive strength requirement when both the following conditions are met:
 Individual strength tests do not fall below the specified strength by more than 12.5% or 3.45
MPa, whichever is least; and
 An individual strength test average with the two preceding individual strength tests meets or
exceeds the specified strength.
The test methods to be used with this specification are:
 AASHTO T-22, Compressive Strength of Cylindrical Concrete Specimens;

 AASHTO T-23, Making and Curing Concrete Test Specimens in the Field.
 SANS 5861 and 5863, Making, Curing and Compressive Strength of Concrete Cubes
Concrete with cube or cylinder compressive strengths that fail to meet acceptance level requirements
shall be evaluated for structural adequacy.
(i) Consistency and Workability

The concrete shall be of suitable workability without the excessive use of water so that it can be
readily compacted into the corners of the formwork and around reinforcement, tendons, and ducts
without segregation of the material.
Workability shall be assessed by means of the slump test, compacting factor test, or VB consistometer
test as directed by the Engineer.
The quantities of mixing water and admixtures to be used will be determined in each case by the
Contractor and approved by the Engineer to obtain a consistency in the range of 25 mm to 100 mm
and no changes shall be made without the Engineer's approval.
Concrete shall be acceptable when the slump, as measured in accordance with AASHTO T-119, is
25mm to 100mm.
The Contractor shall have on-hand at the job site a suitable amount of cement in bags for drying up
over wet concrete and for other purposes.

In the event additional water is required to obtain the specified slump at the job site, the Engineer may
approve adding water normally at the rate of 5 litres per cubic metres, per 25 mm of desired slump
provided a maximum water:cement ratio is not exceeded.
(j) Temperature and Weather Conditions
(i) General
The temperature of the concrete mixture just before placement shall be maintained between 11ºC and
36ºC, except for concrete in bridge decks which shall be between 11ºC and 30ºC.
Work shall not proceed when the temperature of the concrete upon discharge from the delivery vehicle
exceeds the maximum stated above.
The temperature of the concrete shall be measured by the use of a suitable thermometer approved by
the Engineer.
The Contractor shall take all practical measures agreed with the Engineer to keep the temperature of
the mixed concrete as low as possible at all times, consistent with the requirements of this sub-clause.
During hot weather the Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between its discharge from the
mixer and compaction in its final position.
No aggregates in a frozen condition shall be incorporated into the Works but may be used when
thawed out if approved by the Engineer.
Before placing concrete, the formwork, reinforcement, pre-stressing steel and any surface with which
the fresh concrete will be in contact shall be free from snow, ice and frost.
The temperature of concrete shall not be less than 5ºC at the point of delivery. Concrete shall not be
laid when the air temperature in the shade falls below 3ºC; and laying shall not be resumed until the
rising air temperature in the shade reaches 3ºC.
Cement shall not be allowed to come into contact with water at a temperature greater than 60ºC.
Concrete shall not be placed during rain.
(ii) Cold Weather

Concrete shall not be placed during falling temperatures when the ambient air temperatures fall below
7ºC; or during rising temperatures when the ambient air temperature is below 3ºC.
When placing concrete at air temperatures below 5ºC the concrete temperature shall not be below
10ºC.
The temperature of placed concrete shall not be allowed to fall below 5ºC until the concrete has
attained a strength of at least 5 MPa and the Contractor shall be responsible for all protective measure
necessary to ensure this.
When cold weather is reasonably expected or has occurred within seven (7) days of anticipated
concrete placement, the Contractor shall submit a detailed plan for the production, transporting,
placing, protecting, curing and temperature monitoring of concrete during cold weather. The Contractor
shall also include procedures for accommodating abrupt changes in weather conditions. The
placement of concrete shall not commence until the plan is accepted by the Engineer. The Engineer
shall notify the acceptance or rejection of the plan within three (3) days to the Contractor.
All concrete that has been damaged by frost or the formation of ice in the concrete shall be removed
and replaced by the Contractor at his own expense.

The Contractor shall have all material and equipment required for protection available at or near the
site before commencing cold weather concreting.
(iii) Hot Weather

When the ambient air temperature exceeds 32ºC during a concreting operation, the Contractor shall
take measures approved by the Engineer to control the temperature of the concrete ingredients so
that the temperature of the placed concrete does not exceed 25ºC.
Such measures will include spraying aggregate stockpiles with water to promote cooling down by
evaporation and where feasible shading of stockpiles and the area where concreting is carried out.
Curing shall commence immediately after placing of the concrete to prevent excessive moisture loss.
In hot weather, all surfaces that will come in contact with the mix shall be cooled down to below 36ºC.
8406 Handling, Placing and Compaction of Concrete
(a) General
Before placing of concrete the structural excavation and backfill; design and construction of falsework
and forms; construction of reinforcing steel; structural steel; bearing devices; jointing material; and
miscellaneous items shall be performed to the satisfaction of the Engineer according to the relevant
sections of these specifications.
Concrete shall not be placed until the forms; all materials to be embedded; and, for spread footings,
the adequacy of the foundation material; have been inspected and approved by the Engineer.
Concrete shall be transported and placed in a manner that will prevent segregation or loss of
constituent materials and contamination.
Concrete shall not be placed in any part of the works until the Engineer's approval has been given. If
concreting is not started within 24 hours of approval being given, approval shall again be obtained
from the Engineer.
Concreting operations shall only be carried out during daylight hours unless proper lighting
arrangements have been made and lights are in working order by noon. Workmen shall not be allowed
to work double shifts and the Contractor shall provide a fresh team for nightshifts.
The placing and compaction of concrete shall at all times be under the direct supervision of an
experienced concrete supervisor.
Once concreting has begun it shall be carried out in a continuous process between construction or
expansion joints.
The delivery rate; placing sequence; and methods shall be such that fresh concrete is always placed
and consolidated against previously placed concrete before initial set has occurred in the previously
placed concrete.
Concrete shall be placed within 15 minutes from completion of mixing and within one (1) hour from the
start of mixing.
All excavations and other contact surfaces of an absorbent nature such as timber formwork shall be
damp but no free water shall be permitted to remain on these surfaces. The formwork shall be cleaned
internally.
The method of placement used shall not cause displacement of reinforcing steel or other embedded
materials.
Re-tempering the concrete by adding water to the mix shall not be permitted.

Temporary form-spreader devices may be left in place until concrete placement precludes their need,
after which they shall be removed.
During and after placement of concrete, care shall be taken not to damage the concrete or break the
bond with reinforcement.
Once the concrete is set, care shall be taken not to disturb the forms or reinforcing bars that project
from the concrete until it is of sufficient strength to resist damage.
(b) Placing
(i) General
Whenever possible, concrete shall be deposited vertically into its final position.
Where chutes are used the length and slope shall be such as not to cause segregation and suitable
spouts or baffles shall be provided at the lower end to prevent segregation.
The displacement of concrete by vibration instead of direct placing will not be allowed. Concrete shall
not be allowed to fall freely through a height of more than 1.5m.
Care shall be taken when casting bridge decks of substantial thickness to avoid layering of concrete
and the whole thickness shall be placed in one (1) pass. Fresh concrete shall not be placed against
concrete that has been in position for more than 30 minutes unless a construction joint is formed.
Pumping of concrete shall be subject to the approval of the Engineer. Aluminium pipes shall not be
used for this purpose.
In concrete of thickness more than 300 mm, hard clean stone "plums" of mass 15-55 kg may, if
approved, be included to displace concrete for up to 20% of the total volume provided that:
 Such “plums” have no adhering films or coatings;

 No “plums” have a dimension greater than one third of the smallest dimension of the concrete
member or 300 mm whichever is less; and
 Each “plum” is surrounded by at least 75 mm of concrete.
Concrete for columns, substructures and culvert walls, and other similar vertical members shall be
placed and allowed to set and settle for a period of time before concrete for integral horizontal
members, such as caps, slabs, or footing is placed. Such period shall be adequate to allow completion
of settlement due to loss of bleed water and shall not be less than 12 hours for vertical members over
4.5 m height and not less than 30 minutes for members over 1.5 m but not over 4.5 m in height. The
vertical members shall have been in place for at least 7 days and shall have attained its specified
strength before loads from horizontal members are applied.
Rigidly fixed screed forms shall be in place for screeding of the concrete grade and contour.
The form bottom shall be clean and wetted down. All open cracks and holes shall be sealed. A runway
for use in placing concrete shall be supported on the form bottom in such manner as to prevent
contact with the reinforcing steel at all time.
Cement mortar blocks prepared for these purposes shall consist of one part cement to two parts of
sand and shall be cured a minimum of seven (7) days prior to use. Blocking and separation of the top
and bottom reinforcement shall be at a minimum one (1) metre centres, each way.
(ii) Sequence of Placement for Substructures

Loads shall not be placed on finished bents, piers, or abutments until concrete tests from the same
concrete cured under the same conditions as the substructure element indicate that all concrete has at
least 80% of its required 28-day compressive strength.
(iii) Vertical members

For vertical members over 4.5 m in height, the concrete shall be allowed to cure for at least four
(4) hours before placing concrete for integral horizontal members.
For vertical members less than 4.5 m in height, the concrete shall be allowed to cure for at least
30 minutes.
Loads shall not be applied from horizontal members until the vertical member has attained its required
strength.
(iv) Superstructures
Concrete shall not be placed in the superstructure until substructure forms have been stripped
sufficiently to determine the acceptability of the supporting substructure concrete. Concrete shall not
be placed in the superstructure until the substructure has attained the required strength.
Concreting for the superstructures of deck and girder type shall be made in one continuous concreting
operation. The rate of supply and working of the concrete shall be such as to prevent cold joints, or
partial setting of concrete, prior to placing continuous batches. Before casting is authorized the
reinforcing steel shall be placed, spaced, tied and supported.
(v) Arches
Concrete shall be placed in arch rings so that the centring is loaded uniformly and symmetrically.
(vi) Box/Slab culverts

The base slab of box culverts shall be placed and allowed to set 24 hours before the remainder of the
culvert is constructed.
For sidewall heights of 1.5 m or less, the sidewalls and top slab may be placed in one continuous
operation.
For sidewalls greater than 1.5 m but less than 4.5 m in height, sidewall concrete shall be allowed to
cure at least 30 minutes before placing concrete in the top slab.
For sidewalls 4.5 m or higher, sidewall concrete shall be allowed to cure at least 12 hours before
placing concrete in the top slab.
(vii) Precast elements

Concrete shall be placed and consolidated so that shrinkage cracks are not produced in the member.
(viii) Placing underwater

Normally concrete shall only be placed in the dry.
Placing concrete under water shall be allowed only in exceptional circumstances where in the opinion
of the Engineer it is not feasible to dewater before placing.
No concrete shall be placed in flowing water.
Underwater placement of concrete is permitted only for seal concrete and drilled shafts. If other than
seal concrete is used, the minimum cement content shall be increased by 10%.
The concrete mix used for underwater placing shall be specifically designed and approved for this
purpose to ensure good flowability, plasticity, and cohesion. Increased sand and cement contents over
normal mixes will usually be required.
Tremies, concrete pumps, or other approved methods shall be used for underwater concrete
placement. Full details of the method proposed shall be submitted in advance to the Engineer for his
approval. Placing by skip or pipeline will also be considered in certain circumstances.
(ix) Tremies
Watertight tremies shall have a diameter of 250mm or more and the top shall be fitted with a hopper.
Multiple tremies shall be used as required.

Tremies shall be made capable of being rapidly lowered to retard or stop the flow of concrete. At the
start of concrete placement, the discharge end shall be sealed and the tube shall be filled with
concrete.
The tremie tube shall be kept full of concrete to the bottom during placement.
If water enters the tube, the tremie shall be withdrawn and the discharge end resealed.
Continuous concrete flow shall be maintained until the placement is completed.
(x) Concrete pumps

Concrete pumps shall have a device at the end of the discharge tube to seal out water while the tube
is first being filled with concrete.
When concrete flow is started, the end of the discharge tube shall be kept full of concrete and below
the surface of the deposited concrete until placement has been completed.
Underwater concrete shall be placed continuously from start to finish in a dense mass.
Each succeeding layer of concrete shall be placed before the preceding layer has taken initial set. The
Contractor shall use more than one tremie or pump as necessary to ensure compliance with this
requirement.
The concrete surface shall be kept as horizontal as practicable.
Dewatering shall be done after test specimens are cured under similar conditions and the concrete
has gained sufficient strength to resist the expected loads. During and after concreting under water,
pumping or dewatering operations in the immediate vicinity shall be suspended until the Engineer
permits them to be continued.
All laitance or other unsatisfactory material shall be removed from the exposed concrete.
(xi) Placing Methods

Equipment used for placing of concrete shall have sufficient capacity that is designed and operated to
prevent mix segregation and mortar loss. Equipment that causes vibrations that could damage the
freshly placed concrete shall not be used.
Equipment with aluminium parts that come into contact with the concrete shall not be used in placing
of concrete. Set or dried mortar shall be removed from inside surfaces of placing equipment.
Concrete shall be placed as near as possible to its final position. Concrete shall not be placed in
horizontal layers greater than 450 mm thick.
The vibrator capacity shall be suitable to consolidate and merge the new layer with the previous layer.
Concrete shall not be placed at a rate that, when corrected for temperature, exceeds the design
loading of the forms.
Unconfined concrete shall not be dropped more than 1.5 m when placing. Concrete may be confined
by using a tube fitted with a hopper head or other approved device that prevents mix segregation and
mortar spattering. This does not apply to cast-in-place piling when concrete placement is completed
before initial set occurs in the concrete placed first.
Concrete pumps shall be operated so that a continuous stream of concrete without air pockets is
delivered at the tube discharge.
Conveyor belt systems longer than 165 m when measured from end to end of the total belt assembly
shall not be used for placing concrete. The belt assembly shall be arranged so that each section
discharges into a vertical hopper to the next section without mortar adhering to the belt. A hopper,

chute, and deflectors shall be used at the discharge end of the conveyor belt system to cause the
concrete to drop vertically.
(xii) Compaction
Concrete shall be fully compacted by approved means during and immediately after placing. It shall be
thoroughly worked against the formwork around the reinforcement tendons, ducts, and embedded
fittings and into corners to form a solid mass free from voids.
The concrete shall be free from honeycombing and planes of weakness and successive layers of the
same lift shall be thoroughly bonded together. In no case shall the depth of a lift exceed 600 mm.
When placing operation would involve dropping the concrete more than 1.5 m, the concrete shall be
dropped through a tremie or chute as required.
Unless otherwise agreed by the Engineer concrete shall be compacted by means of vibrators. Internal
vibrators shall be capable of producing not less than 10 000 cycles/minute; and external vibrators not
less than 3 000 cycles/minute. Sufficient stand-by vibrators shall be held available in case of
breakdown.
Vibrators shall be applied by experienced labour and over vibration resulting in segregation, surface
water and leakage shall be avoided. Contact with reinforcement and formwork shall, as far as
practicable be avoided when using internal vibrators. Concrete shall not be subjected to disturbance
by vibration within 4 to 24 hours after compaction.
Whenever vibration is applied externally, the design of the formwork and positioning of the vibrator
shall be such as to ensure efficient compaction and avoidance of surface blemishes all subject to prior
Special attention shall be given to the compaction of concrete in the anchorage zones and behind the
anchor plates and in all places where high concentrations of reinforcing steel or cables occur.
In such cases where the placing and compaction of concrete is difficult a mix containing small size
aggregate may be used but only with the approval of the Engineer and after a mix containing such
aggregate has been designed and tested. Sufficient number of vibrators shall be provided to
consolidate each batch as it is placed.
External form vibrators shall be used only when the forms have been designed for external vibration
and when internal vibration is not possible.
The concrete shall be vibrated at the point of deposit and at uniformly spaced points not farther apart
than 1.5 times the radius over which the vibration is visibly effective.
Vibrators shall not be used to move concrete and shall be inserted vertically and withdrawn slowly
from the concrete.
The vibration shall be of sufficient duration and intensity to thoroughly consolidate the concrete, but
not to cause segregation and at any one point long enough to cause localised areas of grout to form.
Reinforcement bars shall not be vibrated in order to vibrate the concrete.
Hand held vibrators shall conform to Table 8406/1. Rubber coated vibrators shall be provided when
epoxy coated reinforcement is used.

Table 8406/1: Hand Held Vibratory Requirements
Head Diameter Frequency Radius of Action

(mm) (vibrations/minute) (mm)
19 to 38 10,000 to 15,000 75 to 125
31 to 63 9,000 to 13,500 125 to 250
50 to 88 8,000 to 12,000 250 to 475
8407 Construction Joints
(a) General
Concreting shall be carried out continuously up to the construction joint shown on the Drawings or as
approved. Where concreting has to be interrupted due to an emergency (such as breakdown of the
mixing plant or the occurrence of unsuitable weather), a construction joint shall be formed at the place
of stoppage in the manner which will least impair the durability, appearance, and proper functioning of
the concrete.
Unless otherwise shown on the Drawings the exact position of horizontal construction joints shall be
marked on the formwork by means of grout checks in order to obtain truly horizontal joints.
Stub columns or stub walls on footings shall be cast integrally with the footings and not afterwards.
(b) Preparation of Surfaces

When the concrete has set and while it is still “green”, the surface film and all loose material on the
construction joint shall be removed by means of a water jet assisted by light brushing to expose the
aggregate, but without disturbing the aggregates and leaving a sound, irregular surface. Where this is
not possible the surface film should be removed after the concrete has hardened by mechanical
means appropriate to the degree of hardness to the concrete so as to expose the aggregate and leave
a sound, irregular surface. The roughened surface shall be washed with clean water to remove all
laitance, dirt, and loose particles.
(c) Placing Fresh Concrete at Construction Joints

When fresh concrete is placed the same day as the construction joint was formed the fresh concrete
shall be cast directly against the face of the construction joint.
When concreting recommences a day or more after the forming of the construction joint the following
procedure shall be followed:
 The construction joint shall be kept continuously wet for a period of at least two (2) hours
before concreting starts but shortly before re-concreting, further application of water shall
cease so that the surface is just damp when further concreting has to commence.
 Any dirt, excess water, and loose particles shall be removed prior to starting re-concreting.
 For horizontal construction joint surfaces a freshly mixed slurry consisting of sand, cement and
water mixed in the same proportions as used in the concrete shall be applied approximately
10 mm thick in the construction joint surface immediately ahead of concreting. The slurry must
still be in a plastic state when applied.
 For vertical construction joint faces, a thin coat of a freshly mixed paste of neat cement and
water, using as little water as is practical, shall be applied to the construction joint immediately
ahead of concreting.

 Epoxy resins specially designed for bonding old concrete to new shall be used at construction
joints where so directed by the Engineer. The preparation of the construction joint surface and
the application of the epoxy resin shall be strictly in accordance with the manufacturer’s
recommendations and the Engineer's instructions. The actual brand and type of resin used
shall be subject to the Engineer's approval.
(d) Bonding
Unless otherwise shown on the plans, horizontal joints may be made without keys; and vertical joints
shall be constructed with shear keys. Surfaces of fresh concrete at horizontal joints construction joints
shall be rough floated sufficient to thoroughly consolidate the surface and intentionally left in a
roughened condition.
Shear keys shall consist of formed depression in the surface covering approximately one -third of the
contact surface. The forms for key shall be bevelled so that removal will not damage the concrete.
All construction joints shall be cleaned of surface laitance, curing compound and other foreign
materials before fresh concrete is placed against the surface of the joint.
(e) Bonding and Doweling to Existing Structures

When new concrete is shown on the plans to be bonded to existing concrete structures, the existing
concrete shall be cleaned and flushed. When the plans show reinforcing dowels grouted into holes
drilled in the existing concrete at such construction joints, the holes shall be drilled by methods that will
not shatter or damage the concrete adjacent to the holes. The diameters of the drilled holes shall be
6 mm larger than the nominal diameter of the dowels unless shown otherwise on the Drawings. The
grout shall be neat cement paste of Portland cement and water. The water content shall be not more
than 15 litres per 50 kg of cement. Sufficient grout shall be placed in the holes so that no voids remain
after the dowels are inserted. Grout shall be cured for a period of at least three (3) days or until the
dowels are encased in concrete.
When specified or approved by the Engineer, epoxy may be used in lieu of Portland cement grout for
bonding of dowels in existing concrete. When used, epoxy shall be mixed and placed in accordance
with the manufacturer's recommendations.
8408 Expansion and Contraction Joints
(a) Open joints

Open joints shall be formed with a wooden strip, metal plate, or other approved material.
Joint forming material shall be removed without chipping or breaking the corners of the concrete.
Reinforcement shall not be extended across an open joint.
(b) Filled joints

Pre-moulded expansion joint filler shall be cut to the shape and size of the surface being jointed.
The joint filler shall be secured on one surface of the joint using galvanized nails or other acceptable
means and spliced according to the manufacturer's recommendations.
After form removal, all concrete or mortar that has sealed across the joint shall be removed and neatly
cut.
All joint gaps 3 mm or wider shall be filled with hot asphalt or other approved filler.
All necessary dowels, load transfer devices, and other devices shall be placed as shown on the plans
or as directed.

(c) Steel joints

Plates, angles, or other structural shapes shall be fabricated accurately to conform to the concrete
surface.
Joint opening shall be set to conform to the ambient temperature at the time of concrete placement.
The joints shall be securely fastened to keep them in the correct position.
(d) Water stops

Water stops shall be of copper, plastic or rubber water stops according to AASHTO requirements.
(e) Compression joint seals

One-piece compression joint seals shall be used for transverse joints and the longest practicable
length for longitudinal joints.
Joints shall be cleaned and dried; and spalls and irregularities shall be removed.
A lubricant/adhesive shall be applied as a covering film to both sides of the seal immediately before
installation.
The seal shall be compressed and placed in the joint as recommended by the manufacturer and the
seal shall be in full contact with the joint walls throughout its length.
All seals that are twisted, curled, nicked or improperly formed shall be removed and discarded. All joint
seals that elongate more than 5% of their original length when compressed shall be removed and
reinstalled. All excess lubricant adhesive shall be removed before it dries.
(f) Elastomeric expansion joint seal

Install the joint according to the manufacturer's recommendations and in conformance with the plans.
8409 Finishing Plastic Concrete
(a) General
Finishing of plastic concrete shall be executed in accordance with the requirements of Division 8200 of
(b) Striking of Formwork

Formwork shall be removed in accordance with the minimum requirements stipulated in Table 8409/1

Table 8409/1: Minimum Period before Striking Formwork for Concrete for Structures
Minimum Period for Striking

Surface Temperature of Concrete
Type of Formwork
t°C (any temperature between 0°C
16°C 7°C
and 25°C)
Vertical formwork to 300
columns, walls and large 12 hours 18 hours hours
beams t  10
100
Soffit formwork to slabs 4 days 6 days hours
t  10
250
Props to slabs 10 days 15 days hours
t  10
230
Soffit formwork to beams 9 days 14 days hours
t  10
360
Props to beams 14 days 21 days hours
t  10
8410 Curing Concrete
(a) General
Curing shall begin immediately after the free surface water has evaporated and the finishing is
completed.
If the surface of the concrete begins to dry before the selected curing method can be implemented, the
concrete surface shall be kept moist using a fog spray of water without damaging the surface.
Surfaces to be rubbed shall be kept moist after forms are removed and curing shall commence
immediately following the first rub.
Top surfaces of bridge decks shall be cured using the liquid membrane curing compound method
combined with the water method. Liquid membrane curing compound shall be applied immediately
after finishing.
The water cure shall be applied within four (4) hours after finishing. All concrete shall be cured
uninterrupted for at least seven (7) days.
If pozzolan, in excess of 10% by mass of the Portland cement, is used in the mix, the concrete shall be
cured uninterrupted for at least ten (10) days.
(b) Forms in-place method

For formed surfaces, the forms in place shall be left without loosening.
If forms are removed during the curing period to facilitate rubbing, forms shall only be stripped from
those areas able to be rubbed during the same shift. During rubbing, the surface of the exposed
concrete shall be kept moist. After the rubbing is complete, the curing process shall be continued using
the water method or by applying a clear curing compound for the remainder of the curing period.
(c) Water method

The concrete surface shall be kept continuously wet by ponding, spraying, or covering with material
that is kept continuously and thoroughly wet.
Covering material may consist of cotton mats, multiple layers of burlap, or other approved material that
does not discolour or otherwise damage the concrete.

The covering material shall be covered with a waterproof sheet material that prevents moisture loss
from the concrete. Adjacent sheets shall be lapped at least 150mm and all seams tightly sealed with
pressure sensitive tape, mastic, glue, or other approved methods; and all material shall be secured so
that wind will not displace it.
Sheets that are broken or damaged shall be immediately repaired.
The curing by water shall never be less than seven (7) days by constant and continuous wetting or
ponding; or by using wet Hessian cloth; and as directed by the Engineer depending on the project
climate.
(d) Liquid membrane curing compound method

Liquid membrane method shall not be used on surfaces to receive a rubbed finish.
Liquid membrane shall be used on construction joint surfaces only if the compound is removed by
sandblasting before placement of concrete against the joint.
Type 2, white pigmented, liquid membrane according to AASHTO M-148 shall be used only on the top
surfaces of bridge decks or on surfaces not exposed to view in the completed work and Type 1 or 1-D
clear curing compounds on other surfaces.
Membrane curing solutions containing pigments shall be mixed before use and shall be continuously
agitated during application and the equipment shall be capable of producing a fine spray.
Curing compound shall be applied at a minimum rate of 3 litres per 10 square metres in one or two
uniform applications. If the solution is applied in two applications, the first application shall be followed
with the second application within 30 minutes and shall be applied at right angles to the first
application.
If the membrane is damaged by rain or other means during the curing period, a new coat shall be
immediately applied over the damaged areas.
(e) Steam curing (precast units)

The method of curing adopted shall be subject to the Engineer's approval and shall not cause staining,
contamination, or marring of the surface of the concrete.
The curing period shall be continuous for at least five (5) days for concrete made from Portland
cement, at least two (2) days for that made with rapid hardening Portland cement.
When the temperature of concrete falls below 5ºC these minimum-curing periods shall be extended by
the period during which the temperature of the concrete was below 5ºC.
(f) Curing concrete with sliding formwork

When using sliding formwork, the concrete shall be protected against the weather and rapid drying out
by means of a 4 m wide skirt attached to the lower perimeter of the formwork and hanging over the
working platform. The skirt shall consist of hessian in summer months. In winter months, canvass or
other suitable material shall be used. The skirt shall be weighted at the bottom to prevent it flapping
around in windy conditions.
Curing of the concrete shall be accomplished by means of a fog spray to keep it wet continuously for
the period stated above or until a curing compound is applied. Wetting of the concrete shall be by
means of a fixed spray bar along the full length of the sliding formwork. The spray bar shall be
connected to a suitable high pressure water supply. Wetting shall be discontinued when the ambient

air temperature drops below 5ºC and care shall be exercised to ensure that the water does not erode
the fresh concrete surface.
8411 Pipes and Conduits

No pipes and conduits other than those shown on the Drawings shall be embedded in the concrete
without the Engineer's approval.
The clear space between such pipes and any reinforcement shall be at least 40 mm or the maximum
size of the aggregate plus 5 mm whichever is the greater. The amount of concrete cover over pipes
and fittings shall be at least 25 mm.
The ends of all ferrules used for bracing formwork shall be neatly finished off to the details shown on
the Drawings. Where no details are given on the Drawings ferrules shall be cut back and the holes
filled in with mortar and finished off flush with the concrete surface.
8412 Precast Concrete

This clause applies to all reinforced and pre-stressed concrete members other than precast concrete
piles, culverts and pipes in as far as they are dealt with separately elsewhere in the Specifications.
All precast members shall be manufactured in accordance with the requirements specified for cast in-
situ members in as far as these requirements are relevant. In addition the following shall apply:
 The Contractor shall take all necessary safety measures and precautions during the handling
and erection of precast members and for the stability of members as positioned prior to
casting-in.
 Where concrete members are precast off site, the manufacturer shall keep, and make
available to the Engineer, full records of all concrete mixes and strength tests pertaining to the
members cast. The Contractor shall notify the Engineer in advance of the casting dates to
arrange for inspection and testing of precast members.
 For the purpose of identification all members shall be marked with paint in neat lettering with
the member number shown on the Drawings or ordered by the Engineer; and an identification
number relating to the manufacturing records, letters etc shall be so positioned as not to be
visible when the member is placed in its final position in the completed structure.
 All precast members that have been chipped, cracked, warped or are otherwise damaged, to
the extent that such damage will, in the opinion of the Engineer, prejudice the appearance,
function or structural integrity of the members, shall be rejected or where so allowed, repaired
to the satisfaction of the Engineer.

Item 84.01 Cast in situ concrete

(a) (Class of concrete and part of structure or use indicated) ......................... cubic metre (m³)
(b) etc for other classes of concrete and other uses or parts of the structure ............................
.....................................................................................................................cubic metre (m³)
The unit of measurement for cast in situ concrete shall be the cubic meter of concrete in place.
Quantities shall be calculated from the dimensions shown on the Drawings or as authorised. No
deduction in volume measured for payment shall be made for the volume of any reinforcing steel,
inserts and pipes or conduits up to 150 mm in diameter embedded in the concrete.
The tendered rate shall include full compensation for procuring and furnishing all the materials; storing
the materials; providing all plant; mixing, transporting, placing and compacting the concrete; forming
the inserts; construction joints (except mandatory construction joints) and contraction joints; curing and
protecting the concrete; repairing defective surfaces; and finishing the concrete surfaces as specified.
Payment shall distinguish between the different classes of concrete.
Item 84.02 Manufacturing pre-cast concrete members ........................................ Number (No)

(description of member with reference to Drawing)
The unit of measurement shall be the number of complete members or elements of each type and size
in position in the Works.
The tendered rate for each pre-cast member shall include full compensation for concrete work;
formwork; curing and safeguarding; and for reinforcing steel.
Item 84.03 Transporting and erecting pre-cast concrete members .................... Number (No)
(description of member and approximate mass to be given)
The unit of measurement shall be the number of pre-cast concrete members of each type and size
placed into position.
The tendered rate for each pre-cast member shall include full compensation for all work, costs and
equipment required for transporting, stacking, erecting and installing the pre-cast concrete member in
its final position, complete as specified.
Item 84.04 Portal and rectangular (Box or Slab) culverts

(a) Complete with pre-cast invert slabs (size and type indicated) ................... linear metre (m)
(b) Without pre-cast invert slabs (size and type indicated) .............................. linear metre (m)
The unit of measurement for prefabricated portal or rectangular culverts shall be the linear metre of
culvert laid as shown on the Drawings or as directed by the Engineer.
The length shall be measured along the soffit of the culvert.
The tendered rates shall include full compensation for supplying; testing; loading; transporting and off-
loading the culverts; providing and placing fine-grained materials where required for the installation of
culverts; and installing, laying and jointing the culverts as specified; including cutting them on the site,
and waste.
Payment shall be made separately for floor slabs and inlet and outlet structures of cast in-situ
concrete.
Payment shall distinguish between the different sizes and types of culverts and between culverts
installed with or without prefabricated floor slabs.
2
Item 84.05 Epoxy bonding of new concrete surfaces to old ....................... Square metre (m )
The unit of measurement shall be the square meter of new concrete surface bonded to old by means
of an approved epoxy bonding agent as set out in the specifications.
The tendered rate shall include full compensation for preparing the surfaces and for furnishing and
applying the bonding agent, and for chamfering the concrete on visible joints, complete as shown on
the drawings.

Item 84.06 Demolishing existing concrete

(a) Plain concrete (Member indicated) ............................................................ Cubic metre (m³)
(b) Reinforced concrete (Member indicated) .................................................... Cubic metre(m³)
The unit of measurement shall be the cubic metre of plain or reinforced concrete demolished for each
member, or portion thereof, scheduled separately in the Bill of Quantities.
The tendered rate shall include full compensation for all labour, plant and equipment required to
demolish the existing concrete; and all operations related to the disposal of the product of the
demolition. The tendered rate shall also include full compensation for any necessary measures to
ensure no debris falls into rivers and for any debris that has fallen into rivers to be recovered.

Division 8500: Timber Structures
8501 Scope
This work consists of furnishing, preparing, erecting, and painting of structural timber of the stress
values and sizes. It also includes all required yard lumber and hardware of the sizes and grade
specified, all in accordance with the design shown on the plans or as directed by the Engineer.
8502 Material for Timber Structures
(a) Untreated Structural Timber and Lumber

Structural timber, lumber, and piling shall conform to AASHTO M 168.
No boxed-heart pieces of the approved timber shall be used in outside stringers, floor beams, caps,
posts, sills, or rail posts. Boxed-heart pieces are defined as timber so sawn that at any point in the
length of a sawn piece, the pith lies entirely inside the four faces.
(b) Treated Structural Timber and Lumber

Treated structural timber and lumber shall conform to AASHTO M 168. All dimensional cuts and
incisions in the wood shall be made before pressure treatment.
The wood shall be treated according to AASHTO M 133.
When wood is to be painted, the Contractor shall use water borne ammoniacal copper arsenate or
chromated copper arsenate preservative.
(c) Hardware
Bolts, nuts, drift bolts and dowels may be mild steel. Washers may be cast iron ogee or malleable iron
castings unless structural washers are specified.
Bolts and nuts shall be square headed and unless otherwise stated nails shall be cut or round wire of
standard form. Spikes shall be cut or wire spikes, as specified.
All hardware shall be galvanized according to AASHTO M-111 or cadmium plated according to
AASHTO M-299.
Ring or shear plate timber connectors shall be of approved design and made of non-corrosive metal.
(d) Yard lumber

Yard lumber shall be of the kinds and grade called for on the Drawings. Round poles and posts shall
be of the kinds indicated on the Drawings.
(e) Structural Shapes, Rods, and plates

All structural shapes, rods, and plates shall be of structural steel or wrought iron, as specified or
indicated on the Drawings, meeting the requirements prescribed in Divisions 8300 and 8800 of this
specification, ot the Particular Specifications.
No welds will be permitted in truss rods, or in main members of trusses or girders.
(f) Paint
Paint for timber structures shall conform to the following:
 Primer: FSS TT-P-25, TT-P-96D, or TT-P-001984.

 Paint: FSS TT-P-102 class A, TT-P-96D, TT-P-102F, or TT-P 19D.

 The paint shall be white unless otherwise specified.
(g) Preservative Treatment of Timber
(i) Description
Treated timber shall be structural timber, lumber and piling conforming to the requirements of sub-
clause 8502(b).
Preservative treatment for timber, lumber, guardrail posts and piling shall be in accordance with the
following specifications. The material to be treated will normally be inspected prior to treatment and the
inspection of the treatment process will be made while the process is actually taking place.
(ii) Treating Plant Equipment

Plants for treating lumber and timber shall be equipped with thermometers and gauges necessary to
indicate and record accurately the conditions at all stages of treatment, and all equipment shall be
maintained in a condition satisfactory to the Engineer.
The apparatus and chemicals necessary for making the analyses and tests required by the Engineer
shall be provided by the Contractor.
(iii) Preservatives
Preservatives shall conform to the specifications shown in Table 8502/1.
Table 8502/1: Preservatives for Timber
Preservatives Specifications
Creosote AWPA P 1
AWPA P 2
Creosote-coal tar solution
AWPA P 3
Creosote-petroleum solution
Petroleum for blending with creosote AWPA P 4
Pentachlorophenol AWPA P 8
Solvents used in pentachlorophenol AWPA P 9
solutions
Acid copper chromate AWPA P 5
Ammoniacal copper arsenite AWPA P 5
Chromated copper arsenite AWPA P 5
Chromated zinc chloride AWPA P 5
Flour chromed arsenate phenol AWPA P 5
Tests of the preservatives shall be made in accordance with AASHTO M 133 for the particular
preservative involved.
(a) General
Excavation and backfill for timber structures shall be performed in accordance with Division 8100 of
this specification.
The Contractor shall furnish the required structural lumber and timber of stress grade.
The ground under and in the vicinity of all stored material stacks shall be cleared by the Contractor of
weeds, rubbish, or other unacceptable material.
The bottom layer of material shall be placed at least 200 mm above the ground level.
Sufficient support shall be provided to prevent sagging.

Workmanship shall be first-class throughout. Only competent bridge carpenters shall be employed and
all framing shall be true and exact.
Unless otherwise specified, nails and spikes shall be driven with just sufficient force to set the heads
flush with the surface of the wood. Deep hammer marks in wood surfaces shall be considered
evidence of poor workmanship and sufficient cause for removal of the workman responsible for them.
(b) Storage of Materials

All lumber and timber on the site of the work shall be stacked to prevent warping.
When required by the Engineer, it shall be protected from the weather by suitable covering.
The materials shall not be covered with impervious membranes such as polyethylene film during dry
weather.
Individual wrappings shall be slit full length or punctured on the lower side to permit drainage of water.
Untreated material shall be open-stacked at least 300 mm above the ground surface and so piled to
shed water. The material shall be stacked in layers on spacers (stickers) that extend across the full
width of the stack to allow for free air circulation and all stickers shall be aligned vertically and spaced
at regular intervals.
Treated timber shall be close-stacked to shed water.
(c) Treated Timber

Treated timber shall be framed before treatment and shall be handled carefully without dropping,
breaking of outer fibres, or bruising or penetrating the surface with tools. Cant-dogs, hooks, or pike-
poles shall not be used.
All cuts and abrasions in timber or lumber shall be treated with three (3) brush coats of the same type
of preservative used in the original treatment.
Before driving bolts, all holes bored after treatment shall be impregnated with the same preservative
using equipment suitable for proper application of the preservative and all unused holes shall be
plugged with preservative treated plugs.
(d) Untreated Timber

In structures of untreated timber, the following surfaces shall be coated thoroughly with two coats of
hot creosote oil or any preservative approved by the Engineer before the timber is assembled:
 Ends, tops, and all contact surfaces of posts, sills, and caps;
 Ends, joints, and contact surfaces of bracing and truss members;
 Surfaces of timber bumpers and the back faces of bulkheads;
 Other timber that will be in contact with earth.
(e) Holes for Bolts, Dowels, Rods, and Lag Screws

All holes shall be bored before using preservative to treat the wood. Bore holes for round drift bolts
and dowels shall be bored 1.5 mm smaller in diameter than that of the bolt or dowel to be used. The
diameter of holes for square drift bolts or dowels shall be equal to the side dimension of the bolt or
dowel.
Holes for machine bolts shall be bored with a bit of the same diameter as that of the bolt.

Holes for lag screws shall be bored with a bit not larger than the body of the screw at the base of the
thread and the depth of lag screw boltholes shall be 25mm less than the length under the screw head.
(f) Bolts and Washers

Washers of the size and type specified shall be used under all bolt heads or nuts in contact with wood.
Cast-iron washers shall be used when the timber is in contact with the ground.
Cast-iron washers shall have a thickness equal to the diameter of the bolt, and the diameter of the
washer shall be four times its thickness. All nuts shall be checked or burred effectively with a pointed
tool after final tightening, to prevent turning.
(g) Countersinking
Countersinking of nuts and bolt heads shall be done wherever smooth faces are required by the
Contract.
Recesses formed for countersinking, except in railings, shall be painted with an approved preservative
and, after bolts or screws are in place, the holes shall be filled with hot pitch or other approved filler.
(h) Framing
Treated piles shall not be slabbed or trimmed for fitting sway or sash braces.
All gaps that occur between braces and piles shall be filled with treated blocks so that the bracing is
securely fastened to the piles
(i) Framed Bents

Mudsills shall be firmly and evenly bedded to solid bearing and tamped in place.
Concrete pedestals for the support of framed bents shall be finished carefully so that sills or posts will
bear evenly upon them.
Dowels for anchoring sills and posts shall be set when the concrete is cast and shall project at least
150 mm above the tops of the pedestals.
Sills shall have true and even bearing on mudsills, piles, or pedestals. They shall be drift bolted with
bolts extending into the mud sills or piles for at least 150 mm. Where possible, all earth shall be
removed in contact with sills for free circulation of air around the sills.
(j) Caps for all Bents

Timber caps shall be placed to obtain even and uniform bearing over the tops of the supporting posts
or piles with their ends in alignment.
All caps shall be secured with drift bolts and set approximately at the centre of and extending at least
230 mm into the posts or piles.
(k) Bracing
The ends of bracing shall be bolted through the pile, post, cap, or sill. Bracing at intermediate
interdivisions with posts or piles shall be bolted or spiked with wire or boat spikes, as required. In all
cases galvanized spikes shall be used in addition to bolts.
All bracing shall be secured firmly against the pile or cap to which it is bolted.
Shims shall be provided and placed as necessary to prevent bending the bracing more than 26 mm
out of line when bracing bolts are tightened.
Shims shall not be used, where the space between the bracing and cap or pile is less than 26 mm.

Where the space between the bracing and the cap or pile is 38.5 mm ± 13 mm, 2 ogee washers shall
be placed with their narrow faces together or other approved washers on each bolt which passes
through the space.
Where the space between the bracing and the cap or pile is over 50 mm, wooden shims of the proper
thickness shall be used. The wooden shims shall be fabricated from white oak or from the same
treated wood used in the structure. Built-up wooden shims shall not be used. Wooden shims shall be
made from a single piece of lumber with the width not less than 100 mm and the length not less than
the width of the bracing measured along the cap or pile. Any treated member shall not be adzed,
trimmed, or cut to avoid the use of shims.
(l) Stringers
Size stringers shall be sized at bearings and shall be placed in position so that knots near edges will
be in the top portions of the stringers.
Outside stringers may have butt joints with the ends cut on a taper, but interior stringers shall be
lapped to take bearing over the full width of the floor beam or cap at each end.
The lapped ends of untreated stringers shall be separated by at least 13 mm for air circulation and
shall be securely fastened by drift-bolting where specified.
When stringers are 2 panels in length the joints shall be staggered.
Cross bridging between stringers shall be securely toe-nailed with at least 2 nails in each end.
All cross-bridging members shall be cut for a full bearing at each end against the sides of the stringers.
Unless otherwise specified in the contract, cross bridging shall be placed at the centre of each span.
(m) Plank Floors or Decks

Planks shall be the grade specified and shall be surfaced on four sides (S4S). Single-ply timber
floors/decks shall consist of a single thickness of planks supported on stringers. The planks shall be
laid heart side down with 6 mm space between them for seasoned material and with tight joints for
unseasoned material.
Each plank shall be securely spiked to each stringer. The planks shall be carefully graded as to
thickness and so laid that no two adjacent planks vary in thickness by more than 3 mm.
Two-ply timber floors/decks shall consist of two layers of flooring/decking supported on stringers. The
lower layer shall be pressure-treated with creosote oil. The top layer may be laid either diagonally or
parallel to the centreline of the roadway, as specified, and each floor/deck piece shall be securely
fastened to the lower layer. Joints shall be staggered at least 900 mm. If the top layer is placed parallel
to the centreline of the roadway, special care shall be taken to securely fasten the ends of the
flooring/decking. The ends of top layer members at each end of the structure shall be bevelled.
(n) Transversely Nail-Laminated Decks

Pieces for laminated or strip floors/decks shall have a nominal thickness of 50 mm laminations, and
shall be surfaced one edge hit or miss 3 mm scant (SIE-H or M 1/8 inch scant), and one side hit or
miss 3 mm scant (SIS-H or M 1/8 inch scant).
The pieces shall be of the grade specified. They shall be placed on edge and at right angles to the
centreline of roadway. Each piece shall be spiked to the preceding piece at each end and at
approximately 450 mm intervals with the galvanized spikes driven alternately near the top and bottom
edges.

The spikes shall be of sufficient length to pass through two pieces and at least halfway through the
third piece. The size of spikes shall be as shown on the Drawings.
Where timber stringers are used, every other piece shall be toe-nailed to every other stringer.
When steel stringers are used, they shall be securely attached to the pieces using approved
galvanized metal clips.
Pieces shall be of sufficient length to bear on at least four (4) stringers. No splicing of pieces between
stringers will be allowed.
End joints on any one stringer shall be no closer than every third piece.
End joints in adjoining pieces shall be no closer than every second stringer.
(o) Wheel Guards and Railings

Wheel guards and railings shall be accurately framed in accordance with the Drawings and erected
true to line and grade.
Unless otherwise specified, wheel guards, rails, and posts shall be surfaced on four sides (S4S).
Place wheel guards shall be placed in sections not less than 3.60 metre in length.
All rails shall be squarely butt-joined at the posts and the rails shall break joints.
(p) Trusses
Trusses, when completed, shall show no irregularities of line.
Chords shall be straight and true from end to end in horizontal projection and, in vertical projection,
shall show a smooth, corded curve through panel points conforming to the correct camber.
All bearing surfaces and joints shall fit accurately. Uneven or rough cuts at the points of bearing shall
be cause for rejection of the pieces containing the defect.
(q) Drains
Drains shall be provided where indicated on the Drawings.
Drains shall be constructed with galvanize iron linings and shall be arranged to discharge free of the
structure.
(r) Painting
Rails and rail posts shall be painted with three coats of white paint unless otherwise specified on the
Drawings or instructed by the Engineer. Each coat of paint shall be fee from surface defects before the
next coat is applied. The final coat shall have an even and uniform appearance for approval by The
Engineer.
Other parts of the structure shall be painted when so designated on the Drawings.
(s) Acceptance
Material for timber structures will be evaluated by visual inspection and certification. A production
certification shall be furnished with each shipment of structural timber and lumber.
Construction of timber structures will be evaluated by Visual inspection and by measurement as given
under the construction tolerances Division 81100 of this specification.


Untreated and treated structural timber and lumber shall be measured by the thousand meter board
measure (MBM) in the structure. The quantities shall be calculated from nominal dimensions and
actual lengths; except for transversely nail laminated decks. Transversely nail-laminated decks shall
be measured in place after dressing.
The accepted measured quantities shall be paid at the contract price per unit of measurement for the
pay items listed below that are shown in the bid schedule. Payment shall be full compensation for the
work prescribed in this Division.
Item 85.01 Untreated structural timber and lumber ...... thousand meter board measure (MBM)
The unit of measurement shall be in MBM.
The tender rate shall include supply, cutting, fixing painting and finishing of the timber.
Item 85.02 Treated structural timber and lumber .......... thousand meter board measure (MBM)
The unit of measurement shall be in MBM
The tender rate shall include supply, treating, cutting, fixing painting and finishing of the timber.

Division 8600: Pre-stressing
8601 Scope
This Division covers the specification of materials, equipment and methods for the pre-stressing of
structural concrete elements by means of pre-tensioning and post-tensioning in accordance with the
dimensions and details shown in the Contract.
8602 Materials
(a) General
All materials and pre-stressing systems used in the pre-stressing of structural concrete members shall
be subject to approval by the Engineer.
(b) Pre-stressing steel
(i) General
The type of pre-stressing steel shall be designated in accordance with the requirements of sub-
clauses 8602(b)(ii) and (iii).
The Contractor shall keep proper records of all material analyses and test certificates for the batches
of pre-stressing steel used in the works.
Where required by the Engineer, the Contractor shall produce certificates from a recognised testing
authorities certifying compliance of the pre-stressing steel with the specified requirements.
Where pre-stressing steel is available in weld-free lengths (production lengths) and lengths containing
welds (standard lengths), the batches delivered at the site shall be clearly labelled for identifications
purposes.
In no circumstances shall pre-stressing steel after manufacture be subjected to heat treatment other
than provided for in these specifications
(ii) Bars
Cold-worked high-tensile alloy steel bars for pre-stressed concrete shall comply with the requirements
of AASHTO M-275 or otherwise described in the Contract.
(iii) Wires and seven-wire steel strand

Steel wire and seven-wire steel strand for pre-stressed concrete shall comply with the requirements of
AASHTO M-204 and M-203 respectively.
(iv) Straightness
Pre-stressing bars delivered at the site shall be straight. Only small adjustments for straightness may
be made, which shall be done by hand on the site at a temperature above 5ºC and under the
supervision of the Engineer. Where heating of the bars is required, this shall be by means of steam or
hot water. Bars bent in the threaded portion shall not be used.
Pre-stressing wire and strand shall be supplied in coils with a sufficiently large diameter to ensure that
the wire and strand will pay-off straight.
(v) Surface condition

Pre-stressing steel shall be clean, free from faults, imperfections or defects, and without any harmful
films and matter, which may impair adhesion to the grout of concrete. A film of rust is not necessarily
harmful and may improve the bond. It may, however, increase the friction between the tendon and
duct.

Tendons may be cleaned by wire brushing or by passing through a pressure box containing
carborundum powder. Solvent solutions shall not be used for cleaning without the approval of the
Engineer.
Pre-stressing steel shall be delivered at the site suitably protected against damage and corrosion.
Such protection or the use of a corrosion inhibitor, where allowed by the Engineer, shall not have any
deleterious effect on the steel or concrete or impair the bond between the two.
Pre-stressing steel that has sustained physical damage at any time shall be rejected. The
development of pitting or other results of corrosion, other than rust stains, shall be cause for rejection.
(vi) Cutting of Pre-stressing Tendons

All cutting of tendons shall be carried out using either:
 A high-speed abrasive cutting disc or friction saw used at not less than one diameter from the
anchor, or any other mechanical method approved by the Engineer.
 An oxyacetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting
action used not less than 75mm from the anchor, whilst the temperature of the tendon
adjacent to the anchor shall not be greater than 200ºC. Neither the flame nor splashes from
the cutting operation shall come into contact with either the anchorage-s or the tendons.
(vii) Galvanising
Galvanised pre-stressing steel shall not be used unless specified.
(viii) Welds
Pre-stressing steel used in structural pre-stressed concrete shall be weld-free.
Where the steel is supplied in standard lengths, the welds shall be cut out and delivered to the
Engineer.
(c) Anchorage-s and couplers

Anchorage-s and couplers to be used in pre-stressed concrete shall comply with the requirements of
AASHTO LFRD Bridge Construction Specifications and shall be of an approved type, constructed from
durable material completely free from imperfections and shall not damage, distort or kink the pre-
stressing steel in a manner as will result in ultimate tensile strength reduction. They shall resist,
without failure and/or excessive deformation or relaxation of the force in the tendons, the full ultimate
tensile strength of the tendons.
The anchorage-s shall effectively distribute the force in the tendon to the structural member, and the
resulting local stresses and strains in the member shall be so limited as to prevent damage. Unless
otherwise approved by the Engineer, all anchorage-s and couplers shall be provided with appropriately
designed anchorage reinforcement.
Wedges and the insides of barrels or cones shall be clean to allow the free movement and seating of
the wedges inside the taper.
The threads of bars, nuts, anchorage-s and couplers shall be suitably protected against damage and
corrosion. The protection shall be removed at the last moment and the threads properly lubricated
before use.
(d) Ducts
Ducts shall be grout-tight and of such material and configuration that bond forces can be transferred
from the grout to the surrounding concrete.

The properties of the duct material shall be such that no corrosion attack of the pre-stressing steel will
be induced.
The ducts shall be sufficiently flexible to accept the required curvature without kinking, and strong
enough to retain its cross-section and alignment and to resist damage on account of handling,
transporting, tying and contact with vibrators during concreting.
Unless otherwise approved by the Engineer, the thickness of the metal of steel ducts shall not be less
than 0.4 mm.
Metal ducts shall be delivered at the site suitably protected against damage and corrosion. At the time
of Incorporation into the structural member, the ducts shall be free from loose mill scale, loose rust,
lubricants and harmful matter.
Galvanised ducts shall not be used unless specified.
Unless otherwise specified, the internal diameter of the duct shall be at least 10 mm greater than the
diameter of the tendon.
For vertical tendons and where tendons are to be drawn into cast-in ducts, the cross-sectional duct
area shall be at least three times the cross-sectional area of the tendon.
(e) Cable supports

Supports of reinforcing steel or structural steel suitably braced to prevent buckling under load shall be
used to support the cables.
The cable saddles shall be rigid and secured in position by welding or by equivalent mechanical
means to resist both gravitational and buoyancy forces.
Normal web reinforcement shall not be utilised to support cables.
Saddles for external cables shall be of special design and material to ensure low friction and to
prevent the tendon or parts thereof from grooving the surface. The saddle plates shall be curved to the
required radius to prevent the tendon or part thereof from bearing on the end of the plate and shall
incorporate features to ensure that individual bars, wires and strands are seated separately.
(f) Positioning of Tendons and Ducts for Pre-stressing Tendons

Tendons and ducts shall be accurately located and maintained in position both vertically and
horizontally as described in the Contract. Unless otherwise described in the Contract the tolerance in
the location of the centreline of the duct shall be ± 5mm.
Where tendons are described in the Contract as being de-bonded from the concrete, they shall be
covered with sleeves approved by the Engineer. The ends of the sleeves shall be taped around the
tendon to prevent the ingress of grout.
(g) Tendon spacers

Tendon spacers used inside the ducts to separate individual bars, wires or strands of the tendon shall
be of a proved and approved type and manufactured from material which will not induce corrosion of
the pre-stressing steel.
(h) Grout
(i) Materials
In addition to the requirements of sub-clause 8402(d) of these specifications, water shall not contain
more than 500 mg of Cl ions per litre of water.

Only ordinary Portland cement that complies with the requirements of AASHTO M-85 or blended
hydraulic cement complying with the requirements of AASHTO M-240 shall be used.
The temperature of the cement shall be less than 40ºC and the cement shall be stored In accordance
with the requirements of sub-clause 8403(a) of these specifications.
Fine aggregate shall comply with the requirements of sub-clause 8402(c) of these specifications.
The use of fine aggregate shall be subject to the approval of the Engineer and shall be restricted to
grout for ducts with a diameter exceeding 150 mm. The aggregate content in the grout shall not
exceed 30% of the mass of the cement.
The use of admixtures shall be subject to tests having shown that their use improves the properties of
the grout (eg by increasing workability, reducing bleeding, entraining air, or expanding the grout).
Admixtures shall be free from any product liable to damage the steel or the grout itself, such as
halides, nitrates, sulphides, sulphates, etc. The quantity of admixture to be used shall be in
accordance with the manufacturer's instructions.
(ii) Properties of the grout

The mixed grout shall have the following properties:
 The Cl ions content shall not exceed 750 mg per litre.

 The viscosity of the grout measured in accordance with Division 10100 of these specifications,
for horizontal cables shall be 500 to 2 500 cP and for vertical cables 400 to 1 500 cP. The
viscosity of the grout, 20 minutes after mixing, shall not exceed 2 500 cP and 1 500 cP for
horizontal and vertical cables respectively,
 Bleeding at 20ºC measured in accordance with Division 10100 of these specifications, shall
not exceed 2% by volume 3 hours after the grout has been mixed, and the maximum bleeding
shall not exceed 4%. In addition, the separated (bleed) water must be reabsorbed after 24
hours.
 The cube compressive strength of 100 mm cubes made of the grout and cured in a moist
atmosphere for the first 24 hours and then in water at 20ºC shall exceed 20 MPa at 7 days.
(i) Protecting agents for un-bonded tendons

The material used for permanent protection of un-bonded tendons shall have the following properties:
 It shall remain free from cracks and shall not become brittle or fluid within the temperature
range of -20ºC to 70ºC.
 It shall be chemically stable for the entire life of the structure.
 It shall be non-reactive with the surrounding materials (ie concrete, tendons, wrapping or
ducts).
 It shall be non-corrosive or corrosion inhibiting.
 It shall be impervious to moisture and shall be sufficiently tough to withstand the abrasion
caused when a tendon, pre-coated with the material, is drawn into the duct.
 It shall have no appreciable shrinkage or excessive volume increase.
 It shall have a suitable viscosity at ambient temperature or require only moderate preheating
to permit injection

(j) Testing
Pre-stressing steel, anchorage-s and couplers, and grout shall be tested in accordance with the
requirements of Division 10100 of these specifications.
Testing shall be carried out at the frequencies as directed by the Engineer.
(a) Equipment
(i) General
All equipment used shall be in a good working order and properly maintained.
(ii) Tensioning and measuring equipment

Tensioning and measuring equipment shall be such that the tendon force can be established to an
accuracy of ± 2% during any stage of the tensioning operation.
Unless otherwise authorised by the Engineer, the tensioning equipment shall be power driven and
capable of gradually applying a controlled total force without inducing dangerous secondary stresses
in the tendon, anchorage or concrete.
The force in the tendon during tensioning shall be measured by a direct-reading dynamometer (load
cell type) or obtained direct from pressure gauges fitted in the hydraulic system to determine the
pressure in the jacks.
Pressure gauges shall have concentric scale dials, which comply with the requirements of BS EN 837.
The dials shall not be less than 150 mm in diameter and the gauges shall be used within the range of
50 - 90% of their full capacity at maximum service pressure.
When pressure gauges not using glycerine are used, a snubber or similar device shall be fitted to
protect the gauge against any sudden release of pressure. Provision shall also be made for T-
connections for the attachment, when required, of supplementary control gauges.
Only self-sealing connections shall be used in the hydraulic circuit. Where the pressure input pipe is
connected to the jack, a pipe rupture valve shall be installed in the circuit.
Tensioning equipment shall be calibrated before the tensioning operation and thereafter at frequent
intervals, as directed by the Engineer, with a master gauge or proving ring, and the Engineer shall be
furnished with a calibration chart. The load-measuring devices shall be calibrated to an accuracy of
± 2%.
The extension of tendons shall be measured to an accuracy of ± 2% or ± 2 mm, whichever is the

smaller, and wedge slip to an accuracy of ± 2 mm.
(iii) Grouting equipment

 Mixer
Only mechanically operated mixers shall be used with a capability of producing high local turbulences
while imparting a slow motion to the body of the grout.
The mixer shall be equipped with a screen with openings not exceeding 1 mm and shall be capable of
consistently producing grout with a colloidal consistency.
 Agitator
Where the capacity of the mixer is insufficient to fill the duct completely with grout, an agitator shall be
used.
Mechanical agitators only shall be used, which are capable of maintaining the colloidal condition of the
grout fill during the storing and injection processes.

The grout shall be delivered at the structure from the agitator, and the system shall make provision for
recirculating the grout from the pump back to the agitator.
 Injection equipment
The pump shall be of the positive displacement type (piston, screw or similar type), capable of exerting
a constant pressure of at least 10 bars on completely grouted cables and shall incorporate a safety
device for preventing the build-up of pressure above 20 bars.
The pump shall be fitted with a pressure gauge and a valve, which can be locked-off without loss of
pressure in the cable.
The pump shall be capable of delivering grout at a speed as will produce a speed of the grout in the
cable of between 6 and 12 m per minute.
All connections in the pipes and between the pipe and the cable shall be airtight. Only bayonet,
threaded, or similar types of connectors shall be used.
(b) Technical Data

The following technical data for pre-tensioned and post-tensioned structural members required for the
contract will be furnished on the Drawings:
(i) Tendon alignment

A diagram showing the alignment of each tendon or group of tendons in both the horizontal and
vertical planes, together with the horizontal and vertical coordinates, and curve equations of the
centroid of the tendon(s), as may be relevant.
(ii) Tendon system

The design is based on the system shown on the Drawings, but the Contractor may use any suitable
system, which will meet all the specified requirements, subject to approval by the Engineer.
(iii) Tensioning the tendons

Full particulars shall be provided regarding the partial tensioning of the tendons; the stage during
which the tendons shall be tensioned; and the sequence of tensioning to be followed.
(iv) Tensioning force

Detail shall be provided regarding the maximum tensioning force and the effective force at the live
anchorage-s, after transfer, as well as the corresponding stress level in the pre-stressing steel, for
each tendon or group of tendons. The forces shall be given in MN units, and the stress levels will be
expressed as a percentage of the characteristic strength.
(v) Extension
The extension per tendon or group of tendons under the maximum tensioning force shall be provided,
together with the modulus of elasticity (E) on which it has been based. The release to be attained at
each live anchorage, as well as the wedge-slip for which provision has been made shall be specificed.
The Contractor shall show on his Drawings the expected extension based on the actual modulus of
elasticity of the strand as well as the expected wedge slip and any provision for shimming.
(vi) Pre-stressing losses in tendons

The losses allowed for in the design from the causes listed will be given as follows:
 Friction loss: The formula used for determining the tendon/duct friction loss together with the
values adopted for the friction coefficient (u) caused by curvature, and the wobble factor (k)
caused by unintentional variation from the specified alignment.

 Elastic deformation of concrete: The factor, which, when multiplied by the compressive
stress in the concrete adjacent to the tendon, will give the loss caused by the elastic
deformation of the concrete.
 Creep of the concrete: The creep factor, which, when multiplied by the compressive stress in
the concrete adjacent to the tendon, will give the loss caused by the creep of the concrete.
 Shrinkage of the concrete: The stress loss in MPa caused by the shrinkage of the concrete.
 Relaxation of pre-stressing steel: The stress loss in MPa at a stress level of 70% of the
characteristic strength of the pre-stressing steel caused by the relaxation of the pre-stressing
steel.
(vii) Anchorages
The positions where loop or fan-type dead-end anchorage may be used,
(viii) Bursting reinforcement

The primary bursting reinforcement for the pre-stressing system on which the design is based.
(ix) Pre-camber
The pre-camber at intervals not exceeding 0.25 times the span length.
(x) Compressive strength of the concrete during transfer

The compressive strength to be attained by the concrete in the relevant member before transfer may
be effected.
(c) Pre-stressing System

The use of all pre-stressing systems will be subject to approval by the Engineer.
Within one (1) month of the Contract having been awarded, or within a period agreed with the
Engineer, the Contractor shall submit full details regarding the pre-stressing system(s); materials and
equipment intended for use; and the methods proposed in the pre-stressing and related operations.
The Engineer, at his own discretion, may call for further information in the form of detailed drawings;
proof of successful previous use; performance certificates from an approved independent testing
authority; and calculations substantiating the adequacy of the system. The Contractor shall furnish
such information within two (2) weeks of being called upon to do so or within a period agreed with the
Engineer.
If, after investigating all the information, the Engineer is not satisfied that the pre-stressing of the
structural member can be carried out satisfactorily with the pre-stressing system offered by the
Contractor, the Engineer reserves the right to order the Contractor to use any system which is suited
to the work and which is readily available to the Contractor.
Only minor alterations to the concrete dimensions shown on the Drawings will be considered in order
to accommodate the pre-stressing system finally selected. Major alterations occasioned by the pre-
stressing system offered by the Contractor and which is at variance with the tendon system specified
in sub-clause 8603(b) shall be treated as alternative designs and shall be dealt as per the Contract.
(d) Drawings Prepared by the Contractor

All drawings prepared by the Contractor and submitted to the Engineer for consideration shall comply
with the requirements of the Contract.
The Contractor shall submit to the Engineer at least two (2) months before commencing the pre-
stressing work, drawings detailing the layout and alignment for the individual tendons; the cable
supports; modifications to the bursting and other reinforcement; anchorage recesses; tensioning
sequence; tensioning loads and extensions; and requirements for controlling the tensioning
operations.

For the pre-stressing system finally selected, the technical data, which are at variance with the
information given on the Drawings, shall be shown on the Contractor’s drawings.
Each tendon shall be separately numbered for identification.
Where required, the Contractor shall submit calculations in respect of the variation of the tendon force
along the length of the tendon; the expected extension; and the bursting forces.
After approval by the Engineer of the drawings and calculations prepared by the Contractor, no
departure shall be permitted from the forces, stresses and extensions shown thereon, without
authorisation by the Engineer.
The pre-stressing work shall not be commenced before the relevant drawings have been accepted by
the Engineer.
(e) Pre-casting
(i) Casting yard on the site

Subject to approval by the Engineer, precast work may be done at any location selected by the
Contractor.
Before the casting yard is established, the Contractor shall submit plans to the Engineer, which
demarcate the site and detail the layout of the Works, together with a flow diagram of the construction
stages and storage.
(ii) Manufacture off the site

The Contractor shall notify the Engineer in advance of the dates when tensioning of tendons; casting
of members; and transfer will be undertaken.
Within seven (7) days of transfer, the Contractor shall submit to the Engineer a certificate giving the
tendon force(s) and extension(s) attained as well as records of the cube crushing strength and age of
concrete at transfer.
Test results relating to all aspects of the work shall be sent to the Engineer immediately upon their
becoming available.
Where the Engineer requires tests to be conducted on completed members, no member to which the
tests relate shall be dispatched to the site until the tests have been satisfactorily completed and the
members accepted by the Engineer.
(iii) Manufacture
Before work is commenced, details of the manufacture, curing and phasing of the work shall be
submitted to the Engineer for approval. After approval no changes shall be made to the methods or
systems without approval by the Engineer.
The Contractor shall ensure that the specified pre-camber is incorporated in the formwork. The
magnitude of the pre-camber shown on the Drawings shall be subject to variation depending on the
Contractor's construction programme, and the Contractor shall, before manufacture, ascertain in
writing from the Engineer, the increase or decrease in pre-camber. This procedure shall also apply to
the cases where no pre-camber has been specified.
Lifting and supporting the precast members shall be made only at the points marked and provided on
the members.
Precast members which have not been fully tensioned; or fully stage-tensioned; or which have un-
grouted tensioned tendons, shall not be handled without authorisation by the Engineer.

Where members with un-grouted tensioned tendons are handled, control shall be exercised to guard
against possible slip of the tendon at the anchorage.
Pre-stressed precast concrete members shall also comply with the requirements of Clause 8412 of
(f) Pre-Tensioning
During the period between tensioning and transfer, the force in the tendon shall be fully maintained by
some positive means. At transfer, de-tensioning shall take place slowly to minimise any shock which
could adversely affect the transmission length of the tendon.
In the long-line method of pre-tensioning, sufficient locator plates shall be distributed throughout the
length of the bed to ensure that the straight tendons are maintained in their proper position during
concreting. Where a number of units are manufactured in line, they shall be free to slide in the
direction of their length so as to permit transfer of the tendon force to the concrete along the entire
line.
In the individual-mould system, the moulds shall be sufficiently rigid to provide the reaction to the
tendon force without distortion.
Where possible, the mechanism for holding down or holding up deflected tendons shall ensure that
the part in contact with the tendon will be free to move in the line of the tendon so that friction losses
are eliminated. If, however, a system is used which develops a frictional force, this force shall be
determined by testing; and due allowance made therefor.
For single tendons, the deflector in contact with the tendon shall have a radius of not less than 5 times
the tendon diameter for wire, or 10 times the tendon diameter for a strand, and the total angle of
deflection shall not exceed 15º.
Transfer of the tendon force to the concrete shall be effected in conjunction with the release of hold-
down and hold-up forces in accordance with an approved method.
Transfer shall not be effected until compressive strength tests on the concrete show that the concrete
of the particular member has attained a compressive strength of at least the compressive strength
The transmission length is affected by the concrete strength, and the necessary modification for the
concrete strength at transfer shall be made in conjunction with the Engineer.
The tendons shall be cut off flush with the end of the member and the exposed ends covered with a
heavy coat of approved bituminous material or epoxy resin. The cutting of the pre-stressing steel shall
be performed with-4 high-speed abrasive cutting wheel. Flame cutting will not be permitted.
(g) Post-Tensioning
(i) Storage, handling and protection

During storage, transit, and construction after installation, the ducts, pre-stressing steel, anchorage-s
and couplers shall be protected against corrosion, damage or permanent deformation. The manner
and extent of protection required will depend on the environmental factors and the length of time
before permanent corrosion protection is applied; and shall be to the satisfaction of the Engineer.
Under severe corrosive conditions in damp and wet areas and under aggressive conditions the
materials shall be stored in weatherproof sheds.
All materials shall be stored clear of the ground and while in storage shall not be exposed to the
weather.

When pre-stressing steel has been stored for a prolonged period and there is evidence of its
deterioration, the Contractor may be called on to prove by tests that the quality of the steel has not
been significantly impaired and that the pre-stressing steel still complies with the provisions of these
specifications.
Suitable protection shall be provided to the threaded ends of bars.
After fabrication, the cable ends shall be covered with protective wrapping to prevent the ingress of
moisture into the duct.
When the tendon is to be left un-tensioned for a prolonged period after installation, precautions shall
be taken to protect the tendon against corrosion.
Corrosion inhibitors, oils or similar materials used as lubrication or to provide temporary protection
shall be such that they can be completely removed before permanent protection is effected.
(ii) Fabrication
All cutting of pre-stressing steel shall be performed with a high-speed abrasive cutting wheel or by a
method approved by the Engineer. Flame cutting will not be permitted.
Care shall be taken to prevent the pre-stressing steel or anchorage-s from coming into contact with
splashes from flame-cutting or welding processes in the vicinity.
Where possible, all bars, wires or strands tensioned in one operation shall be taken from the same
parcel of pre-stressing steel.
The tendon or cable shall be labelled to show the tendon or cable number, as well as identify from
which parcel the steel has been taken.
Where bars, wires or strands in a tendon are not tensioned simultaneously, tendon spacers shall be
used in accordance with the recommendations for the pre-stressing system or, in the absence thereof
as directed by the Engineer.
Cables shall be fitted at both ends with pipes with a diameter of at least 10 mm for the injection of
grout or protection agents. The ends of the injection pipes shall be fitted with a clamp, valve or device
capable of withstanding a pressure of at least 15 bars without loss of grout or protection agent.
Vent pipes with a diameter of at least 25 mm shall be provided in the duct at every high-point; change
of duct cross-section; and at such intermediate positions as may be shown on the Drawings or
required by the Engineer. The vent pipes shall extend to at least 500 mm above the concrete and shall
comply with the requirements for injection pipes.
Connections to, and joints in ducts shall be made grout-tight by using special duct couplings and
taping. With bonded cables, the length of taping shall not exceed six duct diameters.
Where over-sleeves are used, equal overlaps shall be provided over each length of duct. Joints in
adjacent ducts shall be spaced at least 300 mm apart.
(iii) Installation
The installation of tendons shall not commence until the requirements of clause 8603(d) have been
complied with.
The cable, ducts or extractable core shall be accurately installed to the specified alignment and
securely held in position both vertically and horizontally at intervals appropriate to its rigidity and so as
not to be displaced during concreting, either by the weight of the concrete or by buoyancy.
The spacing of the cable supports shall furthermore ensure that the tendon can be installed to a
smooth alignment without kinks and within the tolerance specified in sub-clause 81103(d).

Cable ducts shall be supported and held in position by means of separate reinforcing steel supports
with a diameter of not less than 16 mm. The transverse bars must be welded to the vertical bars or
must rest on lugs welded to the vertical bars. The spacing of the vertical supports shall not exceed
1 m.
Extractable cores shall not be coated with release agent unless approved by the Engineer.
Unless otherwise shown on the Drawings, the alignment of the tendon within a distance of 1 m from
the live anchorage and/or coupler shall be straight, The tendon axis shall be set perpendicular to the
bearing surface of its anchorage and firmly secured in position so as not to move during concreting.
External anchorage-s shall be seated on a thin mortar bedding to bear evenly on the concrete bearing
surface, and the tendon axis shall be perpendicular to the bearing surface of the anchorage.
Unless otherwise shown on the Drawings, the minimum concrete cover over the outside surface of the
duct or cable support shall comply with the requirements of sub-clause 8303(e), except that, for ducts,
the cover shall not be less than 50 mm.
The spacing of cables will depend on the size of the cable and shall be such that the concrete can be
properly placed and compacted.
Immediately before concreting, the Contractor shall inspect the ducts for grout-tightness and shall seal
all damaged sections.
External tendons shall be installed to the same standards and accuracy specified herein for internal
tendons.
The tendons shall be temporarily supported at regular intervals along the straight length between
saddles. The supports shall consist of rigidly constructed frames secured to the concrete face.
(iv) Concrete strength

Full tensioning of all or some of the tendons shall not commence until the compressive-strength of the
concrete is 35 MPa or the strength shown on the Drawings, whichever is greater.
The compressive strength of the concrete shall be determined from cubes manufactured and tested in
accordance with Sub-clause 10106(e) that have been cured under the same conditions as the
structural member which is to be pre-stressed. The number of concrete cubes required for this
purpose shall be as agreed with the Engineer.
Where initially all or some of the tendons are to be partially tensioned, tensioning shall not commence
before the concrete has attained the compressive strength indicated on the Drawings.
(v) Tensioning
 Preparation
Within 2 hours of the concrete having been placed, the Contractor shall demonstrate that ducts are
free from obstructions; that extractable cores can be removed; and where the design permits, that all
tendons are free to move in the ducts. All water in the ducts shall then be expelled with compressed air
and the cables sealed until tensioning takes place.
Before tensioning commences, the side-forms and other restraining elements shall be released or
removed to give the structural member the freedom to deform under the induced force.
 Tensioning sequence
The sequence of tensioning to be followed shall be as shown on the Drawings and/or on Drawings
prepared by the Contractor in terms of sub-clause 8603(d).
Where partial tensioning of tendons is required, the work shall be executed in accordance with the
details on the Drawings or as specified.

 Assembling the equipment, and safety precautions

The tensioning and measuring equipment shall be assembled for tensioning in exactly the same way
as they are combined for calibration.
The Contractor shall take all the necessary safety precautions to prevent accidents caused by the
malfunctioning or failure of any part of the equipment or material and shall accept full responsibility for
injury sustained by persons or damage to property resulting therefrom.
 Friction
The Engineer may require the Contractor to perform friction tests on designated tendons and to revise
the relevant theoretical extensions to compensate for the discrepancy between the values adopted in
the design and the test results. Payment for these tests shall be borne by the Contractor.
Where applicable, allowance shall be made in the tensioning force to compensate for friction loss in
the jack and in the anchorage.
 Tensioning
Tensioning shall be carried out under the supervision of a technician skilled in the use of the pre-
stressing system and equipment; and the methods of tensioning to be adopted.
Tensioning shall not be commenced before the Engineer has been advised of each tensioning
operation and has given his approval for the work to be started.
The technician and operators shall be supplied with a schedule listing the sequence of tensioning the
various tendons; and a tensioning record sheet showing the theoretical gauge readings, jacking
forces, extensions, release and wedge-slip for each tensioning operation. The record sheet shall
furthermore provide for entering the corresponding information recorded and observations made
during tensioning. A graph of the tensioning force and/or gauge reading versus theoretical extensions
shall, where required, be appended to the record sheet and the actual extensions measured for each
load increment shall be plotted on the graph.
Copies of the completed record sheets and graphs shall be submitted to the Engineer within 24 hours
of the completion of each tensioning operation.
The Contractor shall note that the extensions shall be regarded as an indirect measurement of the
tensioning force and shall serve as a control on the tensioning force applied.
The protruding ends of all bars, wires and strands shall be clearly marked for the accurate
measurement of extension, release and wedge-slip.
Before tensioning is commenced on external tendons, a small load shall be applied to each tendon,
commencing with the uppermost tendon. The force shall be sufficient to take up all slack and prevent
entanglement of the tendons.
The jacking force shall be increased to approximately 5 to 10% of the final jacking force to take up the
tendon slack; to determine the zero position for measuring the extension; to check the gripping
devices; and to check the position and alignment of the jacks. The load shall then be increased
gradually to the full specified tensioning force while intermediate gauge readings and extensions are
recorded at regular intervals.
The final stage of tensioning shall be deemed to have been satisfactorily accomplished when all the
following requirements have been complied with:
 The tendons have been tensioned to the required force.

 The measured extension on individual tendons is within ± 6% of the theoretical extensions.

 The average variation between the measured and theoretical extensions of all the tendons in
a structural member is less than ± 3%.
 The release and/or wedge-slip is within ± 2 mm of the theoretical values.
Where the above conditions are not met individually and collectively, the Contractor shall immediately
advise the Engineer and obtain a ruling as to the procedure to be followed.
In the event of the tendon friction being too high, the Contractor may, subject to approval by the
Engineer, inject an approved lubricant into the duct after first having de-tensioned the tendon.
The cost of the remedial and corrective measures and of the release and re-tensioning of tendons,
which have been occasioned by failure of the operations to meet the above requirements shall be for
the Contractor's account.
After the tensioning has been accepted by the Engineer, the Contractor may cut off the tendons
behind the anchorage as described in sub-clause 8603(f).
(vi) Permanent Protection and bonding of tendons

After tensioning, all tendons shall receive permanent protection against mechanical damage and
corrosion.
Internal tendons shall be protected and bonded to the structural member by cement grout or, when
permitted by the Engineer, by sand-cement grout. Where bond is not important, protection may be
effected by the use of bitumen; petroleum-based compounds; epoxy resins; plastics; and similar
products, all complying with the requirements of Clause 8602 and subject to the approval of the
Engineer.
Tendons located outside the structural section (ie external tendons) shall be encased with a dense
concrete, dense mortar or material sufficiently stable and hard; all subject to approval. The
encasement shall be of the thickness shown on the Drawings.
Where bonding of the tendon to the structural concrete is required, this shall be achieved by bonding
the concrete encasement to the structure with reinforcing steel as detailed on the Drawings.
Protection and bonding of the tendons shall be effected within seven (7) days of the final tensioning of
the tendons, or as specified on the Drawings, but shall not take place without the prior approval of the
Engineer.
After the permanent protection or bonding has been completed the anchorage-s shall be encased in
concrete or grout, which shall be bonded to the old concrete with epoxy resin designed for this
purpose; or shall be completely coated with a corrosion-resistant material. The protection provided
shall in all cases prevent the ingress of water or aggressive agents.
 Preparation of ducts
Before permanent protection and/or bonding of tendons is effected, the following precautions shall be
taken:
 The cables shall be checked for blockages by water or compressed air, being injected.
 Unlined ducts, which are to be filled with grout, shall be flushed with water to wet the concrete.
 Temporary protection or lubricants, which are incompatible with the permanent protection or
bonding, shall be removed by flushing the duct with water or an inert solution, or by any
suitable approved method.
On completion of the above, any excess fluid shall be expelled from the ducts by means of
compressed air or shall be displaced by the protecting agent or grout, as may be relevant.
Any blockages, leakages or factors, which in any way may affect the permanent protection or bonding,
shall immediately be reported to the Engineer.
 Mixing
The mixing of protecting agents shall be strictly in accordance with the manufacturer's instruction.
The aggregate (if used) and the cement shall be measured by mass; and the water by mass or by
volume.
The water:cement ratio by mass shall be as low as possible within the range 0.36 to 0.45; and shall be
consistent with the fluidity requirements of sub-clause 8602(h).
Where an admixture is used, it shall be dissolved in a part of the mixing water before it is added to the
grout.
Mixing shall be commenced by two-thirds (⅔) of the cement being added to the greater part of the
mixing water, and, if used, an additive pre-dissolved in part of the mixing water; and finally the
remainder of the cement. Mixing shall continue for not longer than four (4) minutes after which the
grout shall be continually agitated at slow speed throughout the injection operation.
Where aggregate is used in the grout mix, the word "cement" in the preceding paragraph shall be
replaced by the term "cement/aggregate component".
 Strength of Grout
The compressive strength of 100mm cubes made of the grout shall exceed 17 MPa at 7 days.
Cubes shall be made, cured and tested in accordance with the requirements of ASTM C 31 and
C 942.
 Injection
The injection of permanent protecting agents or grout shall not commence before approval has been
granted that the work may start.
Before injection commences all air shall be expelled from the injection equipment and hoses and all
connections checked for air tightness.
Injection shall take place from the anchorage or coupler, whichever is situated at the lower end of the
cable.
Grout injection shall proceed without any interruption until the cable has been completely filled and
closed off.
The injection of protecting agents shall be strictly In accordance with the instructions, and with the
equipment specified by the manufacturer.
Immediately after mixing, and also during injection, the fluidity of the grout shall be tested at regular
intervals in accordance with sub-clause 8602(j).
Injection shall be continuous at a rate of 6 m to 12 m per minute. As soon as grout with the original
consistency flows from the intermediate vent-pipes, they shall be successively closed. Injection shall
continue until the grout flowing from the vent at the free end is of the same consistency as that of the
injected grout. At this stage the vent shall be closed and the final pressure or a pressure of 5 bars,
whichever is the greater, shall have been maintained on the grout column for 5 minutes before the
valve at the injection end is closed.
All vents shall be kept closed and supported vertically until the grout has finally settled. On vertical
cables, a riser-pips with funnel shall be fitted to the top anchor to ensure that the separated water
migrates upwards and will not remain in the cable.

If an expanding agent is used in the grout mix, the air vents shall be re-opened after grouting to
release any separated water, and shall then again be closed.
Unless a retarder is used in the grout mix, the grout not used within 60 minutes of mixing shall be
discarded.
During the course of grouting 100 mm cubes shall be made for testing in accordance with sub-clause
8602(j). Whilst the grout is being poured into the cube mould, the sides of the mould shall be slightly
tapped to permit any entrapped air to escape.
Precautions shall be taken not to discharge the escaping grout onto railway lines, public roads or
private property.
If a blockage occurs during the course of grouting, the grouting shall be stopped before the maximum
grouting pressure is reached. The duct shall then be flushed out immediately and the blockage
cleared.
Grouting shall not be carried out during very cold weather when the ambient air temperature drops
below 5ºC. Care shall be taken that the ducts are completely free from frost or ice before grouting
commences after frosty weather.
8604 Loss of Pre-stress

Any structural member which has lost all or part of its pre-stress through the failure or malfunctioning
of any part of the pre-stressing component may be rejected by the Engineer and shall be removed
from the works unless approved remedial measures have been successfully carried out on the
member.
No payment will be made in respect of such remedial work or loss suffered by the Contractor in this
regard.

Item 86.01 Pre-stressing tendons

(a) Longitudinal Tendons (size, class & grade stated) ..................................... linear metre (m)
(b) Transverse Tendons (size, class & grade stated) ...................................... linear metre (m)
(c) Vertical Tendons (size, class & grade stated) ............................................ linear metre (m)
The unit of measurement shall be the linear metre which shall be the length of the tendon in metres
between the faces of the anchorage-s. In the case of fan and loop anchorage-s the "length of the
tendon" shall include the length of tendon forming the loop or fan.
The tendered rates shall include full compensation for preparing and submitting the drawings;
supplying, storing, handling and protecting all materials (excluding anchorages and couplers);
fabricating, supporting and installing the cables; lubricating, permanently protecting and bonding the
tendons; for the use of all the equipment; and for all work and incidentals required for completing the
work as specified.
Item 86.02 Anchorages and couplers

(a) Anchorage at jacking end (size stated) ........................................................... number (No)
(b) Anchorage at dead end (size stated) .............................................................. number (No)
(c) Coupler at jacking end (size stated) ................................................................ number (No)

(d) Coupler at dead end (size stated) ................................................................... number (No)
The unit of measurement shall be the number of anchorages of each type and size.
The tendered rates shall include full compensation for supplying, storing, handling, fabricating and
protecting the complete anchorage or coupler assembly; anchorage reinforcing; constructing the
recesses for the anchorage or coupler; tensioning, anchoring and/or coupling; trimming the tendon
ends; using all the equipment; and all work and incidentals required for completing the work as
specified.
The coupler shall include the complete assembly consisting of the anchorage built into the first-stage
construction and the part coupled to it.
The tendered rate for loop or fan anchorages shall exclude the cost of the length of tendon forming the
loop or fan.

Division 8700 Bridge Bearings, Parapets, Railings, Footways, No-

fines Concrete, Water-proofing and Drainage for Structures
8701 Scope
This Division covers:
 The construction, supply and installation of bearings for structures; and the construction of
parapets, railings and footways on structures;
 The supply and installation of all permanent joints which will permit relative movement
between contiguous structural members;
 The manufacture and placing of no-fines concrete used in the Works; and
 The construction and/or installation of drainage works such as weep holes; drainage pipes
and gullies; no-fines concrete blocks; filter lining; and concrete channelling.
8702 Bridge Bearings

Bridge bearings shall be either proprietary or purpose made bearings as described in the Contract.
(a) Material
(i) General
When requested by the Engineer, the Contractor shall submit test certificates from an approved,
independent testing authority to show that the respective materials conform with the specified
requirements, or a certificate from the patent holder or designer certifying that the manufactured item
complies in all respects with relevant product specifications.
Unless otherwise specified, all the materials used for manufacturing the bearings shall comply with the
requirements of AASHTO LRFD Bridge Construction Specifications, Section 18.
(ii) Roofing Felt

Roofing felt shall be in 3-ply and comply with the requirements of the Engineer.
(iii) Elastomer
The elastomer used in the manufacture of bearings shall be natural rubber or synthetic rubber.
Natural rubber shall comply with the requirements of AASHTO M-251.
(iv) Sliding Surface using PTFE

PTFE (Polytetrafluoroethylene) used in conjunction with stainless steel plates to form low friction
sliding surfaces shall be unfilled (virgin) PTFE and comply with the requirements of AASHTO LRFD
Bridge Construction Specifications, Section 18.
The sliding surface of the PTFE may be either smooth or dimpled.
(v) Stainless steel plate

Stainless steel plate used in conjunction with PTFE to form low friction sliding surfaces shall comply
with the requirements of AASHTO LRFD Bridge Construction Specifications, Section 18.
(vi) Stainless steel dowels and bolts

Stainless steel dowels, holding down and anchor bolts shall comply with the requirements of ASTM F
738 and F 836.

(vii) Steel plate

Steel used for plate reinforcement in laminated elastomeric bearings shall comply with the
requirements of ASTM A 570, Grade 36 or ASTM A 611, Grade D.
(viii) Mortar
Mortar bedding for seating of bearings shall be composed of approved sand mixed with either cement
or epoxy resin; or may consist of an approved proprietary mortar. The mortar shall comply with the
following strength requirements.
1 Sand-cement mortar
The 7-day compressive strength of 150mm cylinders made of the mortar and cured in moist
atmosphere for the first 24 hours and thereafter in water at 20ºC shall not be less than 1.5 times the
average contact stress under the bearing; or 15 MPa whichever is the greater.
2 Sand-epoxy resin mortar

The cured compressive cylinder strength of the mortar shall not be less than 2.0 times the average
contact stress under the bearing; or 20 MPa whichever is the greater.
3 Proprietary mortar
The strength requirements for proprietary mortars shall be in accordance with either sub-clause
8702(a)(viii)(1) or (2) as may be relevant.
(b) Concrete Hinges

Concrete hinges shall be constructed in accordance with the details shown on the Drawings.
The throat shall be formed to have rounded chamfers on all sides and with the upper and lower
surfaces at a slight divergence.
The concrete cover to reinforcing steel in the throat shall not be less than 25 mm.
The concrete used in forming the throat of the hinge shall be as specified on the Drawings but shall
not have a 28-day compressive strength of less than 50 MPa. The maximum size of coarse aggregate
in the mix shall not be larger than 10 mm.
Construction joints shall not be formed in the throat area. Where a joint is necessary it shall be formed
as a recess below the throat, level with the top reinforcement mat. The width of the recess shall be
slightly greater than the width of the throat.
Care shall be exercised to eliminate the formation of shrinkage cracks with the throat.
During construction, adequate bracing and support shall be provided to the satisfaction of the
Engineer to prevent rotation in the throat from the time of casting to completion of the structure
incorporating the hinge. During construction the hinge shall not be subjected to conditions that will
include tensile stresses in the throat area.
(c) Roofing Felt

Roofing felt used as bearing strips shall consist of at least three (3) layers laid on the bearing surface
to the dimensions shown on the Drawings.
Where lubricated linings are specified, the roofing felt shall be saturated with vegetable oil and
thereafter liberally dusted with graphite powder before it is laid on the bearing surface.

(d) Elastomeric Bearings
(i) Technical data

The following technical data for the elastomeric bearings required on the Contract will be as shown on
the Drawings, and shall also be shown on Drawings prepared by the Contractor for submission to the
Engineer.
 Design loads and deformations: Showing the critical design and load combination; and
co-existing rotations and horizontal displacements for each or each group of identical
bearings.
 Size and construction of bearing: The size and construction of the bearing pad shall be
designated by :
L x B x (n1(t1) + n2 (t2)),
where
L = length of pad in the transverse direction in mm
B = width of pad in the span direction in mm
t = thickness of individual elastomer layers in mm
n = number of elastomer layers of each thickness
The thickness of the steel plate in reinforced elastomeric bearings shall not be less than 3
mm unless specified otherwise on the Drawings.
The complete bearing shall be encased in a 3 mm thick elastomer layer consisting of the
same elastomer as the rest of the bearing.
 Hardness and type of elastomer: showing the IRHD hardness and type of elastomer (ie
natural or synthetic rubber) from which the specified bearings are to be manufactured.
 Identification: Each bearing shall be identified by a number.
(ii) Alternative bearings

Where alternative bearings are offered by the Contractor, they shall be designed in accordance with
the requirements of the prevailing version of the ERA Bridge Design Manual for the loadings and
deformations shown on the Drawings.
Where a bearing consisting of a different rubber to that, which is specified, is offered, the bearing shall
be redesigned to allow for the variation in hardness and/or type of rubber.
(iii) Inspection and testing

On completion of manufacture of the bearings, the Contractor shall submit bearing pads selected by
the Engineer (or specially manufacture sample pads authorised by the Engineer) to an independent
testing authority for testing. The tests to be undertaken shall be as directed by the Engineer and in
accordance with these specifications.
A variation of ± 20% shall be permitted between the actual and theoretical stiffness for compression
and shear of the elastomer. Where this variation is exceeded, acceptance of the pads shall be at the
discretion of the Engineer.
Copies of test results and certificates for the above mentioned testing shall be timeously submitted by
the Contractor to the Engineer to enable the Engineer to assess the information before the bearings
are installed.
The dimensional tolerances on bearing pads shall comply with the requirements of Division 81100 of
Before the bearings are dispatched to the site of works each bearing (with the exception of large
bearings as provided for in the Particular Specifications) shall be subjected simultaneously to a vertical
load, equal to 150% of the maximum design load; and to a shear distortion equal to 150% of the
maximum design value. The bearings shall be visually inspected for defects by the Engineer and shall
at no stage under this test show any cracks visible to the naked eye; or other defects. The cost of this
testing shall be included in the rate tendered for the supply and installation of the bearing pads.
(e) Proprietary Bearings
(i) General
This clause covers custom-built bearings; and bearings manufactured under license with the exception
of elastomeric bearings. Combined bearings, consisting of an assembly of an elastomeric bearing in
conjunction with a low friction sliding or mechanical component shall fall under this Clause.
The Tenderer may base his tender on any bearing that complied with the specified requirements,
provided that the efficacy of the bearings has been verified by testing and successful previous use.
Evidence of these, as well as information on the bearings durability and suitability for the specified
use, shall be submitted to the Engineer for his consideration.
Details of the product guarantee shall be submitted with the tender.
(ii) Drawings and approval

Prior to manufacture, the Contractor shall submit the following information to the Engineer for his
consideration:
 The manufacturer's specification containing detailed information on the design standards,

materials, manufacture and technical data.
 Drawings showing the bearing construction and installation details.
All bearings used in the permanent works shall be subject to the approval of the Engineer.
(iii) Technical data

The following technical data for the proprietary bearings required on the Contract will be supplied on
the Drawing; and shall also be supplied on the drawings prepared by the Contractor for submission to
the Engineer.
 Design loads and movement: showing the maximum and minimum vertical loads and co-
existing horizontal loads are well as the maximum horizontal load and co-existing vertical load.
 Mechanical fit: showing the mechanical fit on unidirectional and fixed bearings expressed as
the maximum permissible slack (play) between the shear transfer members of the bearing that
are required to resist the applied horizontal loads.
 Identification: each bearing shall be identified by a unique number; the degree of freedom of
movement (fixed, multidirectional or unidirectional); and the type of bearing (spherical,
elastomer-pot, etc).
(iv) Design
The bearings shall be designed to accept the specified load combinations in conjunction with the
maximum eccentricity and rotation without over stressing any part in terms of "Working Load"
requirements or exceeding the requirements for Serviceability Limit State.
Unless specified otherwise in the Particular Specifications or on the Drawings the following shall be
complied with:

 The maximum average pressure on the projected area of the PTFE shall not exceed 45 MPa;
and 30 MPa under maximum load and under dead load respectively. The maximum peak
pressure on the PTFE shall not exceed 60 MPa.
 The maximum average contact stress and maximum edge stress on the concrete or mortar
bedding shall not exceed 20 MPa and 25 MPa respectively.
 The initial peak static coefficient of friction shall not exceed 0.06 and the final static coefficient
of friction shall not exceed 0.04.
 The bearing shall be of overall dimension such that it will fit into the space allowed for the
installation thereof. Major alterations to the contiguous member will not be considered.
(v) Construction
Unless specified otherwise in the Particulat Specifications or on the Drawings the following
requirements shall be complied with:
 The IRHD hardness of the elastomer disc in the pot-type bearings shall 50 ± 5 or 55 ± 5. The
elastomer shall be protected along the edge of the disc by either a metal sealing ring or
capping ring moulded integrally with the disc along the perimeter.
 The thickness of the elastomer disc shall not be less than 0.066 times its diameter.
 The PTFE shall be not less than 3 mm thick and be recessed into the supporting base to a
depth of 0.5 times the thickness of the PTFE ± 0.2 mm.
 The minimum dimension of individual PTFE areas shall not be less than 450 mm and their
spacing shall be such as to ensure equal distribution of stress through contiguous members.
 The thickness of the stainless steel sliding plate shall be not less than 12.5 mm. The plate
shall be either recessed into, or bonded to, the base and, in addition, riveted or bolted to the
base. The edges of the plate shall be sealed to prevent the ingress of moisture between the
plate and the base.
 The slack (play) between shear transfer members of unidirectional and fixed bearings shall not
exceed 2 mm unless specified otherwise.
 Only silicone grease of an approved type shall be used as lubricant between the sliding
surfaces.
 The bearing shall be provided with tight fitting seals to prevent the ingress of dust or
deleterious matter onto the moving parts. The seals shall be of an approved type and
sufficiently durable to last in excess of 50 years.
 The assembled bearing shall be supplied with welded or bolted lugs or straps, temporarily
securing the moving parts firmly in position to ensure that no undesirable relative movement
occurs before or during construction.
 The bearing shall be recessed into adaptor plates or be of such construction as to facilitate
removal of the bearing from the installed position without damage to any part of the bearing or
the surrounding material after raising of the relevant structural member by 15 mm or the
amount specified.
 Anchor and holding down bolts shall be of the material specified on the Drawings.
 Corrosion protection of the exposed steel surfaces, with the exception of the stainless steel
sliding plate, shall consist of the following treatment:
o a/ Preparation of the surfaces by abrasive blast cleaning to SSPC-SP10.
o b/ Metal spraying of the surfaces with zinc to comply with the requirements of
AASHTO M-298.

o c/ Coating of the zinc sprayed surfaces within 4 hours with a sealer compatible with
the zinc and subsequent coat of paint.
o d/ Application of a coat of high build chlorinated rubber paint of minimum 75 micron
dry film thickness and of colour dissimilar to that of the final coat of paint.
o e/ Application of a final coat of high build chlorinated rubber paint a minimum
75 micron dry film thickness and a dark grey colour.
Surfaces in contact with concrete shall receive at least the treatment described in Items a/ and b/
above.
(vi) Inspection and testing

The Engineer may require tests to be carried out to verify compliance of the bearing with the
Specification and/or its performance under the design loads.
Test certificates of all tests carried out shall be made available to the Engineer.
The Contractor shall give the Engineer at least 7-days’ notice prior to final assembly of the bearings to
enable the Engineer or his nominee to inspect the bearing at the factory.
Under no circumstances shall bearings be taken apart and re-assembled on the site except when it is
an unavoidable feature of the installation procedure, in which case the dismantling, installation and re-
assembly shall be under the supervision of qualified personnel.
Rehabilitation, modification and repair work to bearings shall be carried out only in the factory or in an
approved engineering works.
(f) Dowels and Guides

Dowels and guides shall be of such material, design and construction as is detailed on the Drawings.
Where dowels and guides are used in conjunction with bearings they shall not complicate or prevent
the removal of bearings.
(g) Storage and Handling

The bearings shall at all times be stored under cover and clear of the ground, away from sunlight,
heat, oils and chemicals deleterious to the bearings. The bearings shall not be stacked in a manner or
on a surface that will cause distortion of the bearings.
The bearing shall be handled with care to ensure that they are not subjected to impact loads or any
other condition that may be harmful.
(h) Installation
The concrete surface on elements required to receive bearings shall comply with the requirements of
Division 8200 for concrete surface finish. Plastering of the surface will under no circumstances be
permitted.
Before the mortar bedding is constructed the concrete surface shall be chipped back to expose the
aggregate and leave a sound irregular surface. Bonding of the mortar bedding to the concrete surface
shall be in accordance with the manufacturer's recommendations and the Engineer's instructions.
The bedding shall be of dimensions to permit the spreading of load at an angle of 45º through the
bedding. However, the thickness of the bedding shall not be less than 15 mm and 25 mm for
proprietary and elastomeric bearings respectively, nor shall the maximum thickness exceed 50 mm.
Unless shown otherwise on the Drawings, the bearings shall be installed on a horizontal plane and
shall be in full contact with the concrete and bedding surfaces.
To accommodate soffit irregularities and camber in the case of precast members, the member shall be
lowered onto a mortar skim on top of the bearing. The member shall thereafter be propped until the
mortar skim has hardened into a wedge.
The bearings shall be accurately installed to the specified level, alignment and orientation all within the
construction tolerances in accordance with Division 81100 of these specifications and the details
Where the bearing has long sliding plates, these shall be rigidly supported to prevent distortion under
the weight of the wet concrete and construction loads.
Before the bearing is incorporated into the structure it shall be cleaned to remove all deleterious
substances and adhering matter, and thereafter, wrapped in polyethylene sheeting and adequately
sealed to prevent the ingress of mortar and other deleterious material onto the bearing during the
course of construction.
After installation, the polyethylene wrapping shall be removed, the bearing thoroughly cleaned and
lugs removed as directed by the Engineer.
On completion of installation of proprietary bearings the Contractor shall submit to the Engineer a
certificate from the manufacturer or supplier of the bearing certifying acceptance of the installation.
Notwithstanding the issuing of such a certificate, the manufacturer or supplier shall not accept any
responsibility for the installation of the bearings and shall not relieve the Contractor of his
responsibilities under the Contract.
8703 Bridge Parapets, Railings and Footways
(a) Materials
(i) Concrete
All concrete work shall be carried out in accordance with the requirements of Division 8200, 8300 and
8400 of these Specifications.
(ii) Structural steel

Structural steel work shall be carried out in accordance with the provisions of Division 8800 of these
Specifications.
(iii) Structural aluminium

Aluminium castings shall be in accordance with ASTM B 26 and B 247.
Aluminium tubes shall be in accordance with ASTM B 221 and B429..
(b) Concrete Parapets

Concrete parapets shall be either solid concrete parapets or open concrete parapets with concrete
railings.
Concrete railings shall be cast in-situ; or pre-cast; or a combination of the two as shown on the
Drawings. Where possible, pre-cast elements shall be placed with the unformed surface facing
downwards or outwards.
Pipes and fittings to be used for the construction of the ducts in parapets shall be rigid PVC pipes and
fittings with flexible rubber joints which comply with the requirements of AASHTO D 2655.
Duct ends shall be provided with suitable conical wooden stoppers to prevent dirt, concrete and other
deleterious materials from entering the ducts. Two strands of 2.5 mm diameter galvanized steel wire
shall be threaded through each duct. The strands shall extend 2 m beyond each end and be wedged
firmly into position with the wooden stoppers. Inspection eyes for the ducts shall be constructed in
accordance with the details shown on the Drawings.
(c) Metal Railings

Metal bridge railings shall be of steel or other material as shown on the Drawings.
Unless otherwise indicated, all joints in fabricated metal work shall be welded using appropriate
techniques to develop the full strength of the component parts. All fabricated metal works shall be
neatly finished off without sharp edges and with sharp corners rounded off. Metal work shall be
completed with all necessary connections, fastenings and anchor bolts.
Steel work, which is to be cast or grouted into concrete, shall be unpainted and shall be cleaned of
loose rust, scale, oil or other material, which may impair the bond between concrete and steel.
All steelwork shall be painted in the shop and on site in accordance with the provision of Division 9700
of these specifications and as shown on Drawings.
Surfaces which will be inaccessible after erection shall be painted before erection commences. If
called for on the Drawings or in the Bill of Quantities steelwork shall be galvanized and painted;
galvanizing shall be done after fabrication, in accordance with ASTM M 111.
Aluminium work which is to be cast or grouted into; or be in contact with concrete; shall be painted
with two coats of approved bituminous aluminium paint or thoroughly coated with aluminium
impregnated compound on the contact surfaces before installation. Where aluminium work is to be
fixed to steelwork, the aluminium and steel shall be completely isolated from one another with plastic
or other approved washers, gaskets and sleeves. Exposed aluminium work shall be left unpainted.
(d) Bridge Number Plates

Bridge number plates shall be fixed in the positions and according to the method of fixing shown on
the Drawings. The concrete surface on which the plate is to be fixed shall be suitably prepared prior to
the application of any adhesive by roughening and removing all surface laitance.
(e) Concrete Footways

Prior to construction of the footways, including kerbs and copings, the bridge deck shall be accurately
surveyed to establish final lines and levels. The previously cast bridge deck area shall be prepared as
specified in Division 8400 of these specifications to receive footway concrete.
Forms shall be accurately set to final lines and levels and shall be firmly held in position during the
placing of the concrete. Stops at the ends of sections shall be accurately placed to ensure that joints
between adjacent sections are truly perpendicular to the surface of the concrete and at right angles to
the edge of the road or to the skew angle of the deck at the expansion joint.
After removal of the forms the exposed surfaces of the kerbs and copings shall be rubbed in
accordance with the requirements of Division 8200 of these specifications. All edges shall be rounded
to a radius of 20 mm unless otherwise shown on the Drawings.
(f) Concrete Surface Finish Requirements

All formed concrete surfaces shall have a Class F3 surface finish as specified in Division 8200 and all
unformed concrete surfaces shall have a Class U3 surface finish in accordance with Division 8200.
(g) Construction Tolerances

The alignment levels and dimensions of the various items described in this Division shall conform to
the requirements given in Division 81100 of these specifications.

8704 Joints in Structures
(a) General
The Contractor shall not relocate or eliminate a construction joint; or make a construction joint not
shown on the Drawings, without prior approval of the Engineer. This includes emergency construction
joints made necessary by unforeseen interruptions to the concrete pour.
Before fresh concrete is placed at a construction joint, the hardened concrete surface of the joint shall
be roughened and cleaned so that all loose or soft material, free water, foreign matter and laitance is
removed. Care shall be taken not to disturb any reinforcement or damage any adjoining concrete
faces. Just prior to placement, the hardened concrete surface of the construction joint and the
projecting reinforcement shall be washed clean, and the concrete surface saturated with water without
leaving loose material or free water.
Unless otherwise shown on the Drawings or specified, the surfaces of adjoining pours shall be butt
joined. In visually important surfaces the joint shall be straight and true, and free from impermissible
blemishes relevant to its surface finish class.
(b) Movement joints

Movement joints, where specified, shall be one of the following types shown in Table 8704/1:
Table 8704/1: Types of movement joints
Joint Description
Contraction joint: An unreinforced joint with a bond-breaking coating separating the concrete joint
surfaces.
Expansion joint: An unreinforced joint with the joint surfaces separated by a compressible filler.
Control joint: A weakened plane contraction joint created by forming a groove, extending at least one
quarter of the depth of the section, either by means of a grooving tool, by sawing, or by
inserting a pre-moulded strip.
Isolation joint: A joint without keying, dowelling, or reinforcement, which imposes no restraint on
movement in any plane.
(i) Vertical Expansion Joints

Retaining walls shall be provided with vertical expansion joints as shown on the Drawings.
The expansion joints shall consist of jointing material of approved quality, and of thickness shown on
the Drawings, and a depth sufficient to fill the joint. The jointing material shall be neatly cut-to-fit the
surface of the concrete.
(ii) Barrier Contraction Joints

Where barriers are extruded or cast in place, narrow transverse vertical grooves, 20 mm deep, shall
be formed neatly in the surface of the freshly placed concrete to produce contraction joints for the
control of cracking.
The contraction joints shall be at intervals of not more than 3 metres.
(iii) Barrier Expansion Joints

In barriers, expansion joints 15 mm in width for the full depth of the barrier shall be constructed at
intervals not exceeding 15 m unless shown otherwise on the Drawings.
(c) Materials
(i) General
All materials used in the forming, construction and sealing of permanent joints as well as all proprietary
or custom-built expansion joint assemblies shall be subject to the approval of the Engineer.

Jointing materials shall be used in accordance with the manufacturer’s specifications for the location
and type of joint. They shall be compatible when used together; and non-staining to concrete in visible
locations.
Foamed materials for use in compressible fillers shall be closed-cell or impregnated types which do
not absorb water.
Back-up materials for sealant, including backing rods and the like, shall not adhere to the sealant, or
shall be faced with a non-adhering material.
When required by the Engineer the Contractor shall submit test certificates from an approved,
independent testing authority to show that the respective materials conform with the specified
requirements, or a certificate from the patent holder or designer certifying that the manufactured item
complies in all respects with relevant product specifications.
(ii) Joint filler

Where joints are to be filled with jointing materials, including sealant, bond breakers, backing rods,
preformed strips, and the like, the joint surfaces shall be dry and clean before application, and primed
if and as recommended by the joint material manufacturer.
The jointing materials shall be applied so that joints subject to ingress of water are made watertight
where required.
Visible jointing materials shall be finished neatly flush with the adjoining surfaces.
Joint filler shall consist of sheets or strips of the following materials complying with the requirements of
the relevant specifications listed:
 Bitumen impregnated fibreboard and bitumen impregnated corkboard:- U.S. Federal

Specification HH-F-341F or AASHTO Specification M 2213. The bituminous fibre sheet shall
be about 12mm thick sheet specifically manufactured for concrete joints complying with
AASHTO M-153 and conforming to samples and specifications submitted by the Contractor
and approved by the Engineer.
 Resin impregnated corkboard:- U.S. Federal Specification HH-F-341F.
 Flexible foams of expanded polyethylene, polyurethane or polystyrene:- AASHTO M-153.
 Rigid foams of expanded polyethylene, polyurethane or polystyrene:- ASTM D 7174,
ASTM C 578 or AASHTO M-230 as appropriate.
Other joint filler materials may be used if approved by the Engineer after submission of full
specifications and information by the Contractor.
(iii) Sealants
Thermoplastic hot-poured sealants shall comply with the requirements of U.S. Federal Specification
SS-S- 1401B, or AASHTO M-173. The sealants shall be of the rubberised bituminous type containing
a minimum of 20% natural or synthetic rubber.
Thermoplastic cold-applied sealants shall comply with the requirements of U.S. Federal Specifications
SS-S-156.The sealant shall be of the rubberised bituminous type containing a minimum of 20% natural
or synthetic rubber.
Thermosetting chemically curing sealant shall comply with the requirements of U.S. Federal
Specification SS-S-195B, American National Standards Institute Specification ANSI A 116.1 (formerly
ASA A 116.1 and USASI A 116.1.
The final IRHS hardness of the sealant shall be 20 ± 5.

Other sealants may be used if approved by the Engineer after submission of full specifications and
information by the Contractor.
(iv) Preformed elastomeric compression seals

Preformed elastomeric compression seals shall comply with the requirements of ASTM D 2628.
(v) Water stops

Water stops shall be installed such that they are surrounded by fully compacted concrete, and located
so that:
 Their correct positions in the finished work are ensured;

 The proper placing and compaction of the concrete is not inhibited; and reinforcement is not
displaced from its correct position.
Water stops shall be of natural rubber, or flexible PVC, and of the type specified or shown on the
Drawings.
(vi) Accessory materials - Primers

When a primer is to be used in conjunction with the sealant it shall be of the prescribed proprietary
material.
(vii) Accessory materials - Adhesives

Adhesives used in conjunction with preformed seals shall be of a proven and approved type
compatible with the material of the seal.
(viii) Accessory materials - Bond breakers

Polyethylene tape, coated papers, metal foils or similar material may be used where bond breakers
are required.
(ix) Accessory materials - Backup material

Backup material shall consist of compressible materials of correct width and shape, to ensure that
after installation it is in approximately 50% compression and the sealant can be formed to the specified
depth.
Backup materials shall be compatible with the sealant used. Material containing bitumen or volitions
shall not be used with thermosetting chemically curing sealants.
(x) Accessory materials - Filled and unfilled joints

Wherever polystyrene or similar material susceptible to damage is used for forming joints, it shall be
lined with a hard, damage-resistant surface on the side to be concreted. The hard surface shall be
sufficiently resilient to ensure that the joint and surfaces can be formed free from defects.
(xi) Accessory materials - Filled Joints

Filled joints shall be accurately formed to the dimensions shown and with the filler material specified
on the Drawings.
The filler shall be secured in position not to displace during concreting, or thereafter if the filler is to
remain permanently in the joint.
(xii) Accessory materials - Unfilled joints

Unfilled joints shall be accurately formed to the dimensions given on the Drawings, and all external
corners chamfered or rounded for at least 5 mm. The concrete face against which the fresh concrete is
placed shall be treated in good time with an approved bond breaker.
(xiii) Accessory materials - Epoxy Mortar Nosings

Epoxy mortar nosings shall not be used unless detailed on the Drawings and specified in the Particular
Specifications. Where epoxy mortar nosings are permitted, they shall be constructed in accordance
with the requirements specified in the Particular Specifications.
(xiv) Accessory materials - Concrete Nosings

Concrete nosings forming the edges of expansion joints shall be constructed as follows:
After the concrete in the structural member has hardened sufficiently, the protruding ends of the
reinforcing steel shall be bent flat onto the concrete surface of the formed recess.
Before the asphalt surfacing is laid, the recess shall be filled with well-compacted crusher run, sand or
weak mortar. Care shall be exercised to ensure that the concrete surfaces and reinforcing steel are not
contaminated with bituminous agents. Thereafter, the asphalt surfacing shall be laid continuously over
the joint.
The asphalt surfacing corresponding to the width of the nosing shall be cut with a diamond saw blade
and all material removed from the nosing recess. The concrete surfaces of the recess shall then be
roughened to expose the aggregate and leave a sound, irregular surface. The reinforcing steel shall
thereafter be bent, fixed and placed as detailed on the Drawings.
The prepared concrete surfaces shall, immediately before a concrete nosing is cast, be treated with an
approved epoxy resin adhesive. Opposite concrete nosing, separated by a 10 mm thick joint filler strip,
shall be cast simultaneously in accordance with Division 8400 of this Specification, and compacted by
surface vibrator. The nosing shall be screeded flush with the premix surfacing and given a Class U2
surface finish.
Curing shall be in accordance with Division 8400 of this Specification, except that the curing period
shall be ten (10) days.
After the concrete in the nosing has cured for at least three (3) days, the gap between the nosings
shall be enlarged to the requisite dimensions by cutting both sides with parallel diamond saw blades.
The depth of the saw cut shall be such that a ledge is formed along the lower edge of the cut on which
the sealer unit can be supported.
The exposed corners of the nosings shall be ground to have a 10 mm chamfer.
After the joint has been sealed, the wearing surface of the nosings shall be treated with a bituminous
primer to the satisfaction of the Engineer.
Traffic shall not be permitted to pass over the joint before the concrete in the nosing has aged for at
least ten (10) days.
The concrete used in the construction of the nosings shall be Class 40/20 and shall have a slump of
not less than 50 mm and not exceeding 75 mm.
(d) Asphaltic plug type expansion joint systems

Asphaltic plug-type expansion joint systems shall be constructed in accordance with the details on the
Drawings and the specifications and instructions of the suppliers.
(e) Sealing of Joints
(i) General
Sealed joints shall be made watertight over the full length of the joints unless permitted otherwise by
the Engineer.
Unless a water stop is equipped with an effective watertight interlocking system for the joining of
sections, all joints in water stops shall be bonded or fused to have a tensile strength of at least 50% of
that of the unjointed material. At intersections and abrupt changes of direction, water stops shall be
jointed with prefabricated junction pieces.
Restrictions on joint width and temperature at the time of installation of the sealant or seal will be
shown on the Drawings. In the absence of these, and unless specified otherwise, installation shall only
be carried out within the temperature range of 5ºC to 30ºC.
(ii) Preparation of joints

Sawing of joints shall be undertaken at such time as to avoid edge spalling or ravelling.
After removal of the temporary filler material or breaking out of the excess concrete, the inside faces of
the joint shall be wire-brushed or grit-blasted to remove all laitance and contaminants; the joint shall
thereafter be cleaned out and blown out with compressed air to remove all traces of dust.
Solvents shall not be used to remove contaminants from concrete and porous surfaces.
Care shall be exercised to ensure that primers or adhesives are applied only to surfaces that are
absolutely dry.
The primer or adhesive shall be applied strictly in accordance with the manufacturer's instructions.
o o
Unless specified otherwise the primer shall be applied within the temperature range of 10 C t 40 C
and the sealant shall be applied after the curing period of the primer and within the period that the
primer remains active.
(iii) Sealants
Sealants shall be applied strictly in accordance with the manufacturer's instructions by a person skilled
in the use of the particular type of sealant.
Trapping of air and formation of voids in the sealant shall be avoided. The sealant shall be finished to
a neat appearance flush with the edges of the concrete or to the specified depth.
Thermoplastic hot-poured sealants shall not be poured into the joints when the temperature of the joint
is below 10ºC. The safe heating temperature shall not exceed the specified pouring temperature by
more than 10ºC.
Two-part thermosetting chemically curing sealants shall not be applied after expiry of the specified pot-
life period, which commences once the base and activator of the sealant have been combined.
(iv) Preformed compression seals

The seal shall be inserted and secured with a lubricant adhesive covering both sides of the seal over
the full area in contact with the inside faces of the joint. The lubricant adhesive shall be applied
immediately ahead of inserting the seal.
The seal shall be installed with the appropriate equipment in a compressed state such that under the
most adverse condition the seal will remain in compression.
The seal shall at all times be between 5 and 10 mm below the level of the pavement. Any stretching of
the seal that may occur shall not exceed 5%.
Joints in seals shall be bonded or fused and shall be only at positions agreed by the Engineer.
(v) Water stops

Water stops shall be securely and accurately located in position not to displace or deform during
construction.
(f) Proprietary Expansion Joints
(i) General
The use of any type of expansion joint shall be subject to approval by the Engineer.
(ii) Dimensions
Attention is drawn to the overall dimensions of the expansion joints and to the limiting concrete
dimensions of that portion of the structure that is to accommodate the joints.
No alterations to the concrete that will be visible in the final structure or major re-arrangement of the
pre-stressing anchorage-s shall be permitted in order to accommodate joints of excessive size.

All joints to be installed along a skew shall be accurately dimensioned to ensure compliance with Sub-
clause 8703 (f).
Unless otherwise specified, proprietary expansion joints shall include the complete expansion joint
assembly; traversing the roadway, kerbs, footways and median; and shall include the coping and
parapet cover plates as well as the drainage system to drain the expansion joint.
(iii) Design and manufacture

The expansion joint shall be designed to withstand the movements, displacements and rotations
specified on the Drawings in conjunction with loads prescribed in the code of practice adopted for the
design of the structure without overstressing any part in term of "Working Load" requirements or
exceeding the requirement for Serviceability Limit State. Any strengthening required of the supporting
member to resist forces imparted by the joint to the structure, shall be for the Contractor's account.
The specified movements, displacements and rotations shall be accepted without impairment of
efficacy or riding quality of the joint.
The joint shall be vibration free, resistant to mechanical wear and other forms of abrasion, and resist
corrosion; have good riding characteristics, be skid resistant and silent; be of watertight construction or
have provision for the disposal of water, debris or grit collecting in the joint; and be of construction to
facilitate easy inspection, maintenance and repair.
Prior to manufacture of the joints, the Contractor shall submit to the Engineer for his acceptance,
detailed Drawings in accordance with the requirements of Clause 1202 of each expansion joint.
The expansion joints delivered on the site shall be suitably marked to show clearly the sequence and
position of installation.
(g) Installation of Expansion Joints

No expansion joint or part thereof shall be installed prior to the establishment of final surfacing levels
based on a complete level survey of the bridge deck(s). The survey shall be carried out before the
construction of kerbs, channels or bituminous surfacing.
The expansion joint shall form an even surface with the road surface on either side; and the deviation
across and along the expansion joint shall comply with the requirements of Division 81100 of this
specification for cross-section and for surface regularity measured by ordinary straight edge.
On completion of installation of proprietary expansion joint(s) the Contractor shall submit to the
Engineer a certificate from the manufacturer or supplier of the joint(s), certifying acceptance of the
installation. Notwithstanding the issuing of such a certificate, the manufacturer or supplier shall not
accept any responsibility for the installation of the joint(s) and shall not relieve the Contractor of his
responsibilities under the Contract. Payment for the inspection of the joints by the manufacturer or
supplier and the issuing of the certificate will be made by the Contractor.
8705 No-Fines Concrete
(a) Materials
Cement, aggregate and water shall comply with the requirements of Division 8400 of these
specifications.
Each size of aggregate shall be a single size aggregate graded in accordance with AASHTO M-80.

(b) Grades on No-Fines Concrete

No-fines concrete shall be classified by the prefix NF and the size of aggregate to be used Grade NF
19 means no-fines concrete with a 19 mm nominal size aggregate.
The volume of aggregate per 50 kg of cement for each class of concrete shall be as shown in
Table 8705/1:
Table 8705/1: Grades of No-Fines concrete
Grade Aggregate per 50 kg cement

3
NF 38 0.33 m
3
NF 19 0.30 m
3
NF 13 0.27 m
(c) Batching and Mixing

Cement shall be measured by mass or full bags of 50 kg each and aggregate shall be measured by
volume in approved measuring boxes or barrows.
The aggregate shall be moist or wetted before the cement is added. Where drum mixers are used,
about 20% of the water shall be poured into the drum before the aggregate and cement are loaded.
The mixing time in the drum shall be about 45 to 50 seconds.
The quantity of water added shall be just sufficient to form a smooth grout which will adhere to and
coat completely each and every particle of aggregate; and which is just wet enough to ensure that at
points of contact of aggregate, the grout will run together to form as small fillet to bond the aggregate
together. The mix shall contain no more than 20 litres of water per 50 kg of cement.
Mixing shall be carried out in an approved batch type mechanical mixer but small quantities may be
hand mixed.
(d) Placing
No-fines concrete shall be placed in accordance with the procedure agreed by the Engineer. It shall be
placed in its final position within 30 minutes of mixing.
The concrete shall be worked sufficiently to ensure that it completely fills the space to the concreted
and that adjacent aggregate particles are in contact with one another. Excessive tamping or ramming
shall be avoided and under no circumstances shall the concrete be vibrated.
(e) Protection
All no-fines concrete shall be protected from the elements, and loss of moisture.
Protection against loss of moisture shall be accomplished by one or more of the following:
 Retaining formwork in place.

 Covering exposed surfaces with sacking or other approved material kept continuously wet.
 Covering exposed surfaces with plastic sheeting.
No-fines concrete placed during cold weather shall be adequately protected against frost for at least
three (3) days.

8706 Drainage for Structures
(a) Weep holes, drainage pipes and channeling

Weep holes shall not be placed within 40 mm of any reinforcement and shall be carefully cleaned and
kept clean.
Drainage pipes shall be of the material prescribed on the Drawings, and the interior surface shall, on
completion, be smooth and clean.
Cast in-situ concrete channelling shall be provided next to the kerbing if shown on the Drawings and
according to the details provided. Concrete work shall be carried out in accordance with the provisions
of Division 8400 and channelling shall be given a class U2 surface finish as specified in Division 8200.
The channelling shall be bonded to the bridge deck concrete in accordance with the provisions of
Division 8400 of these specifications.
(b) No-fines concrete blocks

Blocks shall be of the class of prescribed no-fines concrete and to the required dimensions and shall
be placed in advance of backfilling. No-fines concrete shall comply with the requirements of Clause
8705 of this Division.
(c) Synthetic-fibre filter fabric

Synthetic-fibre filter fabric shall be of the type and grade shown on the Drawings or specified in the
Specifications.
Filter fabric shall be placed as shown on the Drawings and shall be protected against sunlight and
mechanical damage during storage and installation.
Synthetic-fibre filter fabric shall comply with the requirements of Clause 3107 of this specification.
(d) Crushed stone in drainage strips behind walls

The crushed stone used in drainage strips shall comply with the requirements of Clause 3210 of this
specification for backfilling.
The crushed stone may be wrapped in synthetic-fibre geo-textile and placed in accordance with the
details shown on the Drawings or as instructed by the Engineer.

Item 87.01 Proprietary bearings:

(a) Prime cost sum allowed for purchasing and taking delivery of bearings ... prime cost sum
(b) Percentage on prime cost sum for charges and profit................................ percentage (%)
Payment for purchasing and taking delivery of proprietary bearings, complete with anchor bolts and/or
dowels, shall be in accordance with the provisions of the General Conditions of Contract.
Item 87.02 Installing the proprietary bearings ....................................................... number (No)

The unit of measurement shall be the number of complete bearings of each type and class installed.

The tendered rate shall include full compensation for supplying all the materials not covered under Pay
Item 87.01; constructing the bedding; transporting, handling and storing; and all labour, equipment and
incidentals required for installing the bearings complete as detailed.
The tendered rate shall be final and binding, irrespective of the type or make of bearing finally
installed.
Item 87.03 Bearings (type specified) ....................................................................... number (No)

The unit of measurement shall be the number of complete bearings of each type and class installed.
The tendered rate shall include full compensation for supplying all the materials, including anchor bolts
and/or dowels, constructing the bedding, manufacturing the bearings, transporting, handling and
storing, and all labour, equipment and incidentals required for installing the bearings complete as
detailed.
Item 87.04 Concrete hinges:

(a) (Description of hinge measured per meter)................................................. linear meter (m)
(b) (Description of hinge measured by number) ..................................................... number (No)
The unit of measurement shall be either the linear metre of complete hinge of each type manufactured
and installed; or the number of complete hinges of each type manufactured and installed.
The tendered rates shall include full compensation for supplying all materials, including formwork;
manufacturing the hinges; transporting, handling and storing; sealing the hinges; and all labour,
equipment and incidentals required for installing the hinges complete as detailed.
Item 87.05 Bearing strips ............................................................................... square metre (m²)

2
The unit of measurement shall be the square metre (m ) of bearing area lined with the specified
material irrespective of the number of layers placed.
The tendered rate shall include full compensation for supplying all the materials; transporting, handling
and storing; and all labour and incidentals required for installing the bearing strips complete as
detailed.
Item 87.06 Dowels/guides (type specified) ............................................................. number (No)

The unit of measurement shall be the number of dowels/guides of each type installed.
The tendered rate shall include full compensation for supplying all materials, including anchor bolts;
manufacturing the dowels/guides; transporting, handling and storing; and all labour, equipment and
incidentals required for installing the dowels/guides complete as detailed.
Item 87.07 Concrete parapets ............................................................................ linear metre (m)

The unit of measurement for concrete parapets shall be the linear metre (m) of concrete parapet
complete in accordance with the drawings. Concrete parapets shall include all work above the top
level of the sidewalks or, where not placed on a sidewalk, above the top of the bridge deck concrete,
wing walls or retaining walls and shall also include any kerbing and coping forming an integral part of
the concrete parapet.
The tendered rate for concrete parapets shall include full compensation for all concrete, formwork,
service ducts, drawing wires and accessories. The rates will exclude only the cost of reinforcing steel
as this will be measured and paid for under Pay Item 83.01.

Item 87.08 Steel railings ...................................................................................... linear metre (m)

The unit of measurement for steel railings (type described) shall be the linear metre (m) of railing
complete in accordance with the Drawings.
The tendered rate for steel railings shall include full compensation for all steelwork and corrosion
protection, including fastenings, anchor bolts, mortar bedding, etc, as may be required; and for
erecting the steel railings, complete as specified.
Item 87.09 End blocks .............................................................................................. number (No)

The unit of measurement of bridge end blocks shall be the number of end blocks constructed complete
in accordance with the Drawings.
The tendered rate shall include full compensation for all materials, labour, plant, and other incidentals
required for constructing the end blocks complete as specified, excluding only reinforcing steel.
Item 87.10 Numbers for structures

(a) Number plates ................................................................................................. number (No)
(b) Painted numbers.............................................................................................. number (No)
(c) Numbers formed in concrete ........................................................................... number (No)
The unit of measurement shall be either the number of bridge number plates provided and installed; or
the number of complete numbers painted on the structures; or the number of complete numbers
formed in concrete.
The tendered rates shall include full compensation for providing and installing either the number
plates; or preparing the surface and painting the numbers; or forming the numbers in concrete; and for
all material, labour and equipment required in this connection.
Item 87.11 Proprietary expansion joints

(a) Prime cost sum allowed for purchasing and taking delivery of expansion joints...................
.................................................................................................................... prime cost sum
(b) Percentage on prime cost sum for charges and profit ...................................... percent (%)
Payment for purchasing and taking delivery of proprietary expansion joints shall be in accordance with
the provisions of the General Conditions of Contract (see note 2 below).
Item 87.12 Installation of proprietary expansion joints

(a) (Description of joint measured per meter) ..................................................linear metre (m)
(b) (Description of joint measured by number) .................................................... number (No)
The unit of measurement and payments shall be either the metre of complete joint of each type
installed or the number of complete joints of each type installed.
The tendered rates shall include full compensation for supplying all materials not covered under Pay
Item 87.11; transporting, handling and storing; and all labour, equipment, shaping the recesses, and
incidentals required for installing the expansion joint complete in accordance with instructions (see
notes 1 and 2 below).
The tendered rate shall be final and binding, irrespective of the type or make of joint finally installed.

Item 87.13 Expansion joints

(a) (Description of joint measured per meter) ................................................. linear metre (m)
(b) (Description of joint measured by number) ..................................................... number (No)
The unit of measurement shall be the linear metre of complete expansion joint of each type installed or
the number of completed joints of each type installed.
The tendered rates shall include full compensation for supplying all the materials; manufacturing the
expansion joint; transporting, handling and storing; and all labour, equipment, shaping the recesses;
and incidentals required for installing the expansion joint complete in accordance with instructions (see
notes 1 and 2 below).
Item 87.14 Filled joints:

(a) Filled joints (Description of joint and thickness of joint filler for joints measured per square
meter) ..................................................................................................... square metre (m²)
(b) Filled joints (Description of joint and thickness of joint filler for joints measured per meter)
.............................................................................................................................. metre (m)
The unit of measurement shall be the square metre of filled joint calculated from the surface area of
the joint.
Where the filled joint is 150 mm or less in depth, the unit of measurement shall be the metre of filled
joints measured along the joint centreline. Concrete surfaces formed prior to the construction of the
final surface for completing the filled joint shall be measured under the relevant Pay Items mentioned
in Division 8200 of these specifications, as may be applicable.
The tendered rates shall include full compensation for supplying and installing the joint filler; and all
materials not covered under Pay Item 87.16; and for all labour and incidentals required for completing
the filled joint as - prescribed.
Item 87.15 Unfilled joints

(a) Unfilled joints (Description of joint for joints measured per square meter) ...........................
................................................................................................................ square metre (m²)
(b) Unfilled joints (Description of joint for joints measured per linear meter) ... linear metre (m)
The unit of measurement shall be the square metre of unfilled joint, calculated in accordance with the
joint area.
Where, however, the depth of the joint is 150 mm or less, the unit of measurement shall be the linear
metre of unfilled joint measured along the joint centreline. Concrete areas formed before the final
surface is constructed to complete the unfilled joint shall be measured under Division 8200 payment
items, as may be applicable.
The tendered rates shall include full compensation for providing and applying the bond breaker and all
materials not paid for under Pay Item 87.16; and for the labour and incidentals required for completing
the unfilled joint as prescribed.

Item 87.16 Sealing joints with:

(a) Sealant (description of joint, sealant and size) ...........................................linear metre (m)
(b) Water stop (description of joint, water stop and size) .................................linear metre (m)
The unit of measurement shall be the metre of sealant, seal or water stop of each type installed.
The tendered rates shall include full compensation for supplying all materials; forming or cutting the
concrete to the required shape and size; all labour, equipment and incidentals required for sealing the
joint complete in accordance with the prescription;, and for all waste materials (see note 2 below).
Item 87.17 Cast in situ no- fines concrete ....................................................... cubic metre (m³)
The unit of measurement (class of concrete indicated) shall be the cubic metre of the in situ placed
material.
The provisions of Division 8400 shall apply.
Item 87.18 Precast no-fines concrete units ............................................................ number (No)

The unit of measurement (class of concrete and description of unit) shall be the number of complete
units of each size and type in position in the works.
The tendered rate for each pre-cast concrete unit shall include full compensation for providing all the
materials, labour, plant and formwork required for manufacturing the unit complete as shown on the
drawings; and for transporting and placing the unit in position.
Item 87.19 Drainage pipes and weep holes

(a) Drainage pipes:
(Type and size indicated) ............................................................................linear metre (m)
(Type and size indicated) ................................................................................. number (No)
(b) Weep holes:
(Type and size indicated) ............................................................................linear metre (m)
(Type and size indicated) ................................................................................. number (No)
The unit of measurement shall be either the linear metre of pipe/weep hole or the number of
pipes/weep holes of each type and size of pipe/weep hole completed.
The tendered rates shall include full compensation for supplying all the materials; manufacturing and
installing the pipes; and making weep holes.
Item 87.20 Drainage gullies ...................................................................................... number (No)

The unit of measurement shall be the number of drainage gullies of each type installed.
The tendered rate shall include full compensation for providing all the material and manufacturing and
installing the drainage inlets.
Item 87.21 Synthetic-fiber filter fabric .............................................................. square metre (m²)

The unit of measurement shall be the square metre of filter fabric installed as specified, including the
specified overlap.
The tendered rate shall include full compensation for supplying, cutting and installing the filter fabric;
and for waste material.

Item 87.22 Concrete channeling ....................................................................... linear metre (m)

The unit of measurement shall be the linear metre of completed concrete channeling of each size
constructed.
The tendered rate shall include full compensation for providing all the material, labour, equipment and
expenses required for completing the work.
Item 87.23 Crushed stone in drainage strips .................................................. cubic metre (m³)
The unit of measurement shall be the cubic metre of crushed stone placed in position as specified, in
accordance with the details shown on the Drawings or instructed by the Engineer.
The tendered rate shall include full compensation for procuring, furnishing and placing the crushed
stone; and for wrapping it in synthetic-fibre geotextile as specified.
The geotextile shall be measured for payment under Pay Item 87.21.
Item 87.24 Nose-endings at balustrades ................................................................ number (No)

The unit of measurement shall be the number of nose-endings constructed complete in accordance
with the details shown on the Drawings.
The tendered rate shall include full compensation for all labour, constructional plant and materials
required for filling the recesses with concrete; or nosing material, 20 mm x 20 mm plasti-joint seal
between the end block and the transition block; steel cover plate complete with anchor bolts; and all
incidentals required for constructing the nose-endings complete.
Item 87.25 Concrete transition blocks ................................................................... number (No)

The unit of measurement shall be the number of each size of concrete transition block constructed
complete in accordance with the details shown on the Drawings.
The tendered rate shall include full compensation for all labour; constructional plant; materials; and all
incidentals required for constructing the transition blocks.
Notes:
(1) The cost of forming the open expansion joint(s) shall not be included in the rates tendered for Pay Item 87.12 and Pay Item
87.13 as payment for this work shall be made under Division 8200.
(2) Separate payment shall not be made for supplying and/or installing the seal in proprietary expansion joints or the seal
between concrete or synthetic nosings.
(3) Measurement of and payment for concrete sidewalks (including kerbing and coping) shall be made in accordance with
Divisions 8200, 8400 and 8300.

Division 8800: Structural Steelwork
8801 Scope
This section covers the manufacture, transport and erection of structural steelwork for minor structures
(eg overhead road-sign structures). It does not apply to major steel structures such as steel bridges,
which will be covered in the Particular Specifications when work of this nature is required.
8802 Materials
(a) Structural steel

Structural steel; the dimensions and properties of rolled steel sections; and steel tubes shall comply
with the requirements of AASHTO M-270.
(b) Bolts, nuts and washers

Ordinary bolts and nuts shall be bolts and nuts used for transferring forces by tensile stress,
compressive stress and shear stress without any friction-grip action being considered.
Ordinary bolts and nuts shall comply with the requirements of AASHTO M-164.
Washers for ordinary bolts and nuts shall comply with the requirements of AASHTO M-291.
(c) Friction-grip fasteners:

High-strength friction-grip bolts, nuts and washers shall comply with the requirements of AASTHO M-
164 or M-253M.
Other approved friction-grip fasteners equal to the above may be used.
(d) Welding consumables

Welding electrodes shall comply with the requirements of AWS A5.11 and A5.14.
The quality, handling and storage of all consumables shall be so as to achieve the desirable properties
of the weld metal.
The welding consumables used shall be appropriate to produce weld metal which will yield all the
weld-metal test specimens as specified in AASHTO/AWS D1.5 having both minimum yield and
minimum tensile strengths not less than those of the parent metal.
(e) Test certificates

The Contractor shall submit test certificates, as required by the Engineer, of the structural steel and
anchor bolts that will be used.
8803 Codes of Practice

The design on minor steel structures, where undertaken by the Contractor, shall comply with the
requirements of the prevailing version of the ERA Bridge Design Manual.
8804 Shop Details

Where shop details have not been furnished on the Drawings, the Contractor shall prepare shop
details in accordance with the provisions of the Contract document. Shop details shall be approved
and signed by the Engineer prior to the fabrication of any items.

8805 Fabrication and Assembly
(a) General
All structural steel both before and after fabrication shall be within the tolerances specified in
Division 81100 of these Specifications and shall be flat, straight (unless required to be formed to
another shape) and free from twists.
(b) Marking the steel

At all stages of fabrication, all structural steel shall be clearly marked by grade by means of a suitable
marking system.
(c) Cutting
Steel shall be cut by sawing, shearing with shears, cropping, or flame-cutting.
Edges shall be free from any defects or distortions and all burrs, notches and similar defects shall be
removed.
(d) Holes for fasteners

Holes for fasteners shall not be formed by flame cutting. Holes in light members not thicker than
12 mm or the diameter of the hole, whichever is the smaller, may be punched.
Holes for fasteners of up to 25 mm in diameter shall not be more than 2 mm larger than the diameter
of the fastener and holes for larger fasteners not more than 3 mm larger than the diameter of the
fastener.
Holes for friction-grip fasteners shall be in accordance with AASHTO or ASTM requirements.
All burrs shall be removed from holes before assembly.
(e) Joints in compression

The abutting surfaces of joints dependent on contact for the transmission of load shall be accurately
prepared so that the full area intended for bearing will be in contact as specified in Division 81100 of
(f) Hollow sections

Unless protection against corrosion is provided by other means, the interior of any hollow section shall
be sealed to prevent the ingress of moisture.
Where a sealed hollow member is holed for a fastener or pin, precautionary measures shall be taken
to prevent the ingress of water to the interior of the member.
Vent holes for galvanizing shall be sealed after galvanizing has been completed
(g) Alignment of holes

All matching holes for fasteners or pins shall be accurately aligned so that the fasteners can be
inserted freely through the assembled members in a direction at right angles to the faces in contact.
Drifting for aligning the holes shall not distort the metal or enlarge the holes.
(h) Welding
Welding shall be executed in accordance with the requirements of AASHTO/AWS D1.5 Bridge
Welding Code.
The welding techniques shall be such as to avoid undue distortion and to minimise shrinkage stresses.

All slag shall be removed.
Where required for certain welding:
 The manufacturer shall hold a valid welding procedures certificate and the welding shall be
done by a qualified welder: or
 The welder shall hold a valid certificate of competency for the specified type of welding.
All structural welds shall be full-strength joints.
(i) Bolting
The jointed parts shall be firmly drawn together.
Where necessary, tapering washers shall be used for each bolt head and nut to transfer the
compressive stress over its full surface.
Where bolt-holes have greater than normal clearance, washers shall be placed under the bolt-heads
and nuts.
The length of each bolt shall be such that, after tightening, at least one full thread projects through the
nut on the outside and at least one full thread (in addition to the thread run-out) remains clear between
the nut and the bolt-head.
(j) Welded Stud Shear Connectors

Welded stud shear connections shall conform to AASHTO M-169.
(k) Friction-grip fastening

The use of friction-grip bolts shall be in accordance with AASHTO LFRD Bridge Construction
Specifications. Where use is made of equivalent types of friction-grip fasteners, they shall comply with
the requirements of AASHTO for equivalent fasteners and shall be installed in accordance with the
appropriate requirements of AASHTO.
(l) Riveting
Wherever possible, riveting shall be done with pneumatic equipment.
Riveted units shall have all parts firmly drawn together and aligned before riveting.
Every rivet shall, when driven, completely fill the hole and shall have a well-formed head; or, if
countersunk, fill the countersink completely.
All loose, eccentric-headed, badly formed, burnt or otherwise defective rivets shall be cut out and
replaced.
(m) Trimming
All fabricated steel work shall be neatly trimmed so as not to show any sharp edges. Acute angles
shall be rounded off to a radius of at least 1 mm
(n) Corrosion prevention
(i) Painting
Before removal from the place of manufacture the steelwork shall be painted as specified in
Where the finishing coats are to be applied on the site, the shop painting shall include the application
of an undercoat as specified in Division 9700 of these specifications.
Galvanized steel shall not be painted unless painting is specifically called for in the specifications.
(ii) Sprayed metal coatings

Where the sprayed metal coating of steel surfaces is called for, it shall be done in accordance with the
requirements of AASHTO or ASTM.
The type of metal used shall be as specified, and, unless otherwise specified; the metal coating shall
comply with the requirements of AASHTO or ASTM
(iii) Galvanizing
Where the galvanizing of structural steelwork is required, the members shall be hot-dip galvanized in
accordance with AASHTO M-111.
Structural steel members shall be given an 85-micrometre coating or such other thickness as may be
specified, in accordance with AASHTO or ASTM.
All nuts, bolts, screws and threaded articles shall be hot-dipped galvanized in accordance with the
appropriate requirements of AASHTO or ASTM.
Cut ends and small damaged areas shall be repaired by the application of a zinc-rich paint or by zinc
spraying.
8806 Erection
(a) General
Where specified, details of the method of erection shall be submitted to the Engineer for approval.
All structural steel shall be stored, transported, handled and erected so as not to subject it to undue
stress or damage.
Erection over traffic is not permitted, and a temporary diversion for traffic shall be provided.
Provision for a traffic diversion shall be paid for in accordance with the appropriate items under
(b) Safety during erection

During the erection of a structure, the steelwork shall be bolted, braced or otherwise secured so as to
make adequate provision for all erection loads.
(c) Alignment
Each part of a structure shall be aligned as soon as possible after erection.
Members shall not be permanently connected until sufficiently large members of the structure have
been aligned, plumbed, levelled, and temporarily secured to prevent their displacement during the
erection or alignment of the remainder of the structure.
(d) Corrections
Drift pins, jacking equipment and the like shall not be used for bringing improperly fabricated members
into place.
A moderate degree of cutting and reaming may be done to correct minor misfits if, in the opinion of the
Engineer, this will not be detrimental to the appearance or strength of the structure.
The burning of holes will not be permitted without written approval.
Repairs to painting and site painting shall be effected in accordance with the provisions of

(e) Grouting
The grout shall be poured under and around the base plates of columns after the steelwork has been
finally checked for alignment and height and after the approval of the Engineer has been obtained to
proceed with the grouting.
The column base plates shall be supported by the top and bottom nuts and by steel wedges. The area
under the steel shall be thoroughly cleaned and shall be dust and oil-free; and the concrete shall be
thoroughly rinsed with water to leave the surface clean and moist.
The grout shall be an approved non-shrinking, pourable, cementitious grout.
The grout shall be prepared and applied strictly in accordance with the manufacturer's
recommendations and the Engineer's directives.
Leak-proof formwork shall be used for the pourable grout, and all corners shall be chamfered. The
surface finish shall be class F2 and class U2 as applicable and defined in Division 8200.
8807 Testing
(a) Testing by the Engineer

The Engineer may nominate a testing authority to inspect the works and to conduct such tests as he
may deem to be necessary to test compliance with the Specifications.
Where required, test samples of welds shall be prepared by the Contractor, free of charge.
Payment for these tests shall be made under Pay Item 88.01.
(b) Process control

Welds shall be regularly inspected and tested by the Contractor in terms of his obligations related to
process control, as described in Clause 1202 of these Specifications.
The inspection shall include visual inspection of welds to ensure that no undercutting, uneven lengths,
porosity, or evidence of cracking occurs and that full fusion of the metals has been achieved. In
doubtful areas, cores containing weld metal and adjacent parent material shall, if so required by the
Engineer, be cut out, polished and examined; and the hole repaired.
At least 30% of the welds shall be examined by ultrasonic or radiographic means. If more than 5% of
the examined welds show unsatisfactory results, additional examinations covering all welds shall be
performed.
Certificates of the examination confirming that the steel plates and welds comply with the requirements
of AASHTO or ASTM shall be submitted to the Engineer.
The cost of testing shall be deemed to be included in the rate tendered for Pay Item 88.01.

Item 88.01 Structural steel:

(a) (Structure and steel quality described).................... ............................................... tonne (t)
(b) (Structure and steel quality described).................... ...................................linear metre (m)
(c) (Structure and steel quality described).................... ........................................ number (No)

The unit of measurement shall be either the tonne; or the length in metres of erected permanent steel
structures or articles; or the number of erected permanent steel structures or articles.
Where the unit of measurement is the tonne, the mass of the steel waste caused by punching, drilling,
sheared edges, milling or planning, or metal cut-outs shall not be deducted; and the mass of rivets,
bolts, nuts, washers, welding fillets or temporary bracing shall not be added. In computing the mass of
steel, the nominal mass per unit of length or area will be used; and tolerances and other permissible
deviations will be ignored.
The tendered rates shall include full compensation for preparing shop details not provided on the
Drawings; the supply of all the required materials; fabrication, process control, loading, transporting to
the site; off-loading; and erecting. It shall also include full compensation for all welding; nuts, bolts,
washers and rivets; cutting; waste; and any temporary bracing necessary for transporting and erecting
The tendered rate shall also include full compensation for supplying and pouring the specified grout
under and around the base plates of steel columns; for procuring and supplying all the necessary
labour; construction plant, tools and materials; as well as waste; formwork for the grout; and finishing
to obtain the required surface finish for the grout under and around base plates of steel columns.
Item 88.02 Anchor bolts:

(a) ( Description of each assembly, and grade/type of steel, diameter and length indicated) ....
................................................................................................................... kilogramme (kg)
(b) (Description of each assembly, and grade/type of steel, diameter and length indicated) ....
......................................................................................................................... number (No)
The unit of measurement shall be either the mass in kilogrammes of installed anchor-bolt assemblies
or the number of installed anchor-bolt assemblies.
The tendered rates shall include full compensation for the materials; fabrication; handling; transporting
and installing the anchor-bolt assemblies; including corrosion protection.
Item 88.03 Corrosion protection

(a) Sprayed-on metal:
(Type of metal and thickness or type symbol of coating indicated)........ ................tonne (t)
(Type of metal and thickness or type symbol of coating indicated)............... .......metre (m)
(Type of metal and thickness or type symbol of coating indicated) ................. number (No)
(b) Hot-dip galvanizing:
(Thickness or type symbol of zinc coat indicated)............................................ ......tonne (t)
(Thickness or type symbol of zinc coat indicated)...................................... linear metre (m)
(Thickness or type symbol of zinc coat indicated)........................................... number (No)
The unit of measurement shall be either a tonne; or a linear metre of steel structures or articles
protected against corrosion; or the number of steel structures or articles protected against corrosion.
The quantities are calculated as specified in Pay item 88.01.
The tendered rates shall be extra over the rates for Pay item 88.01 and shall include full compensation
for applying the specified corrosion protection, including surface preparation; materials; labour; tools,
equipment and all incidentals required.
Note:
Payment for painting shall be made under Division 9700 of these specifications.

Division 8900: Stone Masonry Structures
8901 Scope
This work shall consist of stone masonry structures and the stone masonry portions of concrete, steel,
timber, and composite structures, constructed in conformity with the lines, grades, dimensions, and
design shown on the Drawings; and in accordance with this Specification.
8902 Stone Masonry Walls

Stone masonry walls may be plain packed stonewalls (un-mortared or dry-stone walling) with dry joints
or otherwise mortared stonewalls with stones bedded in cement mortar as indicated on the Drawings,
as specified, or as may be ordered by the Engineer.
The minimum mass of each stone used shall be 10 kg and its minimum dimension 75 mm.
(a) Plain packed stonewalls

A foundation trench shall be excavated down to rock; or to material with an adequate bearing capacity
at a minimum depth of 300 mm below ground level.
Large selected stones shall be used for the foundation layer. Flat and stratified stones shall be laid
with the largest dimension in the horizontal plane.
Stones shall be packed individually to stagger the joints and to provide a minimum of voids, and shall
be firmly bedded against adjoining stones.
The spaces between the larger stones shall be filled with spalls securely rammed into place. The
larger stones shall not bear on the spalls used for filling the voids. The top and ends of the wall shall
be neatly finished with selected copingstones.
The appearance of the completed wall shall present an even, tight surface.
(b) Cement-mortared stone walls

The walling shall be constructed as specified in sub-clause 8902(a), with the exception that the stones
shall be wetted and set in a mortar of 4 part sand:1 part cement.
Class A masonry shall have 2:1 sand:cement mortar, and Class B masonry shall have 3:1
sand:cement mortar, unless specified otherwise in the Particular Specification
The exposed parts of the stones on the wall faces shall be cleaned of all mortar by washing or wire
brushing. The mortar shall be flush pointed to the satisfaction of the Engineer, who may require a
capping and end-treatment of the same mortar.
Weep holes shall be provided as prescribed and shall be cleaned of mortar or any other clogging
material that may have entered during construction.
The walling shall be protected from the elements and kept moist for a minimum period of four (4) days
after completion.
8903 Classes of Masonry

The class of masonry used in each part of the structure shall be that called for on the Drawings or
otherwise described in the Contract.

(a) Class A
Class A Masonry shall consist of stones shaped, dressed, and laid broken-coursed in cement mortar in
accordance with Clause 8905 of these specifications.
Class A Masonry shall be more exacting than Class B.
Both classes of masonry are intended for use in any part of a structure, Class A Masonry shall be used
primarily for major structures.
(b) Class B
Class B Masonry shall consist of stones shaped, dressed, and laid broken-coursed in cement mortar
in accordance with Clause 8905 of these specifications.
Class B Masonry shall be less exacting than Class A.
Both classes of masonry are intended for use in any part of a structure, with Class B being used
primarily for minor structures.
(c) Dimensioned Masonry

Dimensioned masonry shall consist of broken-coursed ashlar masonry composed of stone having two
or more dimensions shown on the Drawings. It is intended for use in any part of a masonry structure
where appearance is an important factor, particularly in arch-ring copings, corner trim, etc.
8904 Material Requirements for Stone Masonry Structures
(a) Stone
The stone shall be sound and durable, quarried, or recycled dismantled masonry, and shall be subject
to the Engineer's approval.
The stone shall preferably be native to the vicinity of the work and shall be of a kind that previous use
has proven to be satisfactory for the specified purpose.
The stones shall be properly protected at all times.
In addition to the above requirements, stone for dimensioned masonry shall be free of reeds, rifts,
seams, laminations, and minerals, which, by weathering, would cause discolouration or deterioration.
(i) Sizes and shapes

Each stone shall be free from depressions and projections that might weaken it or prevent it from
being properly bedded, and shall be of such shape as will meet both architecturally and structurally the
requirements for the class of masonry specified.
When dimensions for stones are shown on the Drawings, they shall be of the size shown. When no
dimensions are shown on the Drawings, the stones shall be furnished in the sizes and face areas
necessary to produce the general characteristics and appearance as indicated on the Drawings.
Where headers are required their lengths shall be not less than the width of bed of the widest adjacent
stretcher plus 300 mm.
At least 50% of the total volume of the masonry shall be of stone having a volume of least 0.03 cubic
metres.
(ii) Dressing
The stone shall be dressed to remove any thin or weak portions.

Face stones shall be dressed to provide bed and joint lines with a maximum variation from true line as
follows:
 Class A Masonry 5 mm.

 Class B Masonry 20 mm.
 Dimensioned Masonry True.
(iii) Bed surface

Bed surfaces of face stones shall be normal to the faces of the stones for about 80 mm and from this
point may depart from normal; but not to exceed 25 mm in 300 mm for dimensioned masonry and
50 mm in 300 mm for all other classes.
(iv) Joint surfaces

In all classes of masonry except dimensioned masonry, the joint surfaces of face stones shall form an
angle with the bed surfaces of not less than 45 degrees.
In dimensioned masonry, the joint surfaces shall be normal to the bed surfaces. They shall also be
normal to the exposed faces of the stone for at least 50 mm from which point they may depart from
normal not to exceed 25 mm in 300 mm.
The corners at the meeting of the bed and joint lines shall not be rounded in excess of the following
radii:
 Class A Masonry No rounding

 Class B Masonry 25 mm.
 Dimensioned Masonry No rounding
(v) Arch-ring stone-joint surfaces

Arch-ring stone-joint surfaces shall be radial and at right angles to the front faces of the stones.
They shall be dressed for a distance of at least 80 mm from the front faces and soffits, from which
points they may depart from a plane normal to the face not to exceed 20 mm in 300 mm.
The back surface in contact with the concrete of the arch barrel shall be parallel to the front face and
shall be dressed for a distance of 150 mm from the intrados.
The top shall be cut perpendicular to the front face and shall be dressed for a distance of at least
80 mm from the front.
When concrete is to be placed after the masonry has been constructed, adjacent ring-stones shall
vary by at least 150 mm in depth.
(vi) Stratification
Stratification in arch-ring stones shall be parallel to the radial joints; and in other stones shall be
parallel to the beds.
(vii) Finish for exposed faces

Face stones shall be pitched to line along all beds and joints.
The kind of finish for exposed faces shall be as shown on the Drawings or otherwise described in the
Contract. The following symbols will be used and they shall be understood to represent the type of
surface or dressing specified:
 Fine Pointed (FP): In which the point depressions shall be approximately 10 mm apart with
surface variation not to exceed 3 mm from the pitch line.
 Medium Pointed (MP): In which the point depressions shall be approximately 10 mm apart
with surface variations not to exceed 8 mm from the pitch line.
 Coarse Pointed (CP): In which the point depression shall be approximately 25 to 30 mm

apart with surface variations not to exceed 10 mm from the pitch line.
 Split or seam faced (S): In which the surface shall present a smooth appearance, be free
from tool marks, with no depressions below the pitch line and no projection exceeding 20 mm
beyond the pitch line.
 Rock faced (RF): In which the face shall be an irregular projecting surface without indications
of tool marks: with no concave surfaces below the pitch line, and with projections beyond the
pitch line, when measured in equivalent metric units (eg millimetres), not exceeding the figure
preceding the symbol as used on the Drawings (should imperial measurements in inches still
prevail) or as otherwise described in the Contract (eg "1½ R.F." means projections beyond the
pitch line not exceeding 37 mm). Where a "variable rock face is specified, stones of the same
height of projection shall be well distributed.
Unless otherwise specified on the Drawings, all Class B masonry shall be coarse pointed.
Removal of drill and quarry marks from the faces of stones in cement rubble masonry will not be
required.
(b) Quarry Operations

Quarry operations and delivery of stone to the point of use shall be organized so as to insure keeping
deliveries well ahead of masonry operations.
A sufficiently large stock of stone of the kinds being used in the work shall be kept on the site at all
times, to permit adequate selection of stone by the masons.
(c) Mortar
Mortar shall consist of four parts by volume of fine aggregate or sand to one part by volume of cement
complying with the requirements of Division 8400 of these specifications.
(a) Excavation and backfill

Excavation and backfill shall conform to the requirements of Division 8100 of these specifications,
modified as follows:
 For filled spandrel arches the filling shall be carefully placed in such manner as to load the ring
uniformly and symmetrically.
 The filling materials shall be mainly stone cut debris with preferably flat stone acceptable to
the Engineer and shall be placed in horizontal layers, carefully tamped, and brought up
simultaneously from both haunches.
 Wedge-shaped sections of filling material against spandrels, wings, or abutments will not be
permitted.
 Round gravel stone shall be avoided.
(b) Falsework
Arch centring shall be constructed in accordance with construction drawings submitted by the
Contractor as required by the Conditions of Contact.
Suitable wedges shall be provided for raising or lowering the forms to exact elevation and for taking up
any settlement occurring during loading. Centring shall be lowered gradually and symmetrically so as
to avoid over-stresses in the arch.

When directed, centring shall rest upon approved jocks in order to take up and correct any slight
settlement, which may occur after the placing of masonry has begun.
In general, centring shall be struck and the arch made self-supporting before the railing or coping is
placed. For filled spandrel arches such portions of the spandrel walls shall be left for construction
subsequent to the striking of centres as may be necessary to avoid jamming of the expansion joints.
When, in the opinion of the Engineer, additional falsework and bracing are necessary to hold the
stones in proper position, the Contractor shall construct such falsework and bracing in a manner
satisfactory to the Engineer. Failure of the Engineer to order their construction shall not release the
Contractor from his obligation to build a satisfactory structure.
(c) Selection and Placing

When the masonry is to be placed on a prepared foundation bed, the bed shall be firm and normal to,
or in steps normal to, the face of the wall, and shall have been approved by the Engineer before any
stone is placed. All loose, fractured or otherwise unsuitable material shall be removed prior to the
construction of masonry. The masonry structure shall be adequately keyed on sloping surfaces.
When it is to be placed on foundation masonry, the bearing surface of this masonry shall be cleaned
thoroughly and wetted immediately before the mortar bed is spread.
All masonry shall be constructed by experienced workmen.
Face stones shall be set in random bond so as to produce the effect shown on the plans and to
correspond with the sample section approved by the Engineer.
Care shall be taken to prevent the bunching of small stones or stones of the same size. When
weathered or coloured stones; or stones of varying texture are being used, care shall be exercised to
distribute the various kinds of stones uniformly throughout the exposed faces of the work.
Large stones shall be used for the bottom courses and large, selected, stones shall be used in the
corners. In general, the stones shall decrease in size from the bottom to the top of work.
All stones shall be cleaned thoroughly and wetted immediately before being set; and the bed which is
to receive them shall be clean and moistened before the mortar is spread. They shall be laid with their
longest faces horizontal in full beds of mortar; and the joints shall be flushed with mortar.
(i) Class A Masonry

All stones, excluding exposed faces of individual stones (facing stones), shall be laid with their longest
axis normal to the face of the wall in which the stones are set.
The exposed facing stones, excluding bond stones, shall be parallel to the face of the wall. Bond
stones shall be provided at the rate of not less than one to every square metre of exposed face.
Bond stones shall measure not less than 150mm by 150mm on the exposed face and not less than
450mm in length or the full thickness of the wall if the latter is less than 450mm.
(ii) Class B Masonry

All stones, including exposed faces of individual stones and bond stones, shall be laid with their
longest axis normal to the face of the wall in which the stones are set.
Bond stones shall be provided at the rate of not less than one to every square metre of exposed face.
Bond stones shall measure not less than 150mm by 150mm on the exposed face and not less than
450mm in length or the full thickness of the wall if the latter is less than 450mm.
The stones shall be so handled as not to jar or displace the stones already set.

Suitable equipment shall be provided for setting stones larger than those that can be handled by two
men.
The rolling or turning of stones on the walls will not be permitted.
If a stone is loosened after the mortar has taken Initial set, it shall be removed, the mortar cleaned off,
and the stone re-laid with fresh mortar.
Arch ring stone shall be carefully set to exact position and hold in place with hardwood wedges until
the joints are packed with mortar.
(d) Beds and Joints

The thickness of beds and joints for face stones shall be as shown in Table 8905/1.
Table 8905/1: Bed Thicknesses for Face Stones

Class of
Beds (mm) Joints (mm)
Masonry
Class A 20 to 100 20 to 70
Class B 20 to 120 20 to 100
Dimensioned (see note) 20 to 50
Note: The thickness of beds in dimensioned masonry may vary from 20 mm to 25 mm from the bottom to the top of the
work, but in each course the beds shall be of uniform thickness throughout.
Unless shown otherwise on the Drawings, beds shall not extend in an unbroken line through more
than five (5) stones; and joints through more than two (2) stones.
Joints in dimensioned masonry shall be vertical. In all other masonry, joints may be at angles with the
vertical from 0 to 45 degrees.
Each face stone shall bond with all contiguous face stones at least 150 mm longitudinally and 50 mm
vertically.
At no place shall corners of four (4) stones be adjacent to each other.
Cross beds for vertical walls shall be level and for battered walls may vary from level to normal to the
batter fine of the face of the wall.
All arch-ring joints shall be completely filled with mortar.
(e) Headers
When headers are required they shall be distributed uniformly throughout the walls of structures so as
to form at least one-fifth of the faces.
(f) Backing
The backing shall be built mainly of large stones and in a workmanlike manner.
The individual stones composing the backing and hearting, shall be well-bonded with the stones in the
face wall and with each other.
All openings and interstices in the backing shall be filled completely with mortar or with spalls
surrounded completely by mortar.
(g) Coping
Copings, if called for, shall be as shown on the Drawings.
Where copings are not called for, the top of the wall shall be finished with stones wide enough to cover
the top of the wall, from 0.5 to 1.5 m. in length, and of random heights, with a minimum height of
150 mm. Stones shall be laid in such a manner that the top course is an integral part of the wall.

The tops of the top courses of stone shall be pitched to line in both vertical and horizontal planes.
(h) Parapet walls

Selected stones squared and pitched to line and with heads dressed, shall be used in the ends of
parapet walls and in all exposed angles and corners.
Headers shall be well interlocked and as many as possible shall extend entirely through the wall.
Both the headers and stretchers in the two faces of the wall shall be well interlocked in the heart and
shall comprise practically the whole volume of the wall. All interstices in the wall shall be completely
filled with cement grout or with spalls completely surrounded with mortar or grout.
(i) Facing for Concrete

Unless otherwise specified, the stone masonry shall be constructed before placing concrete. When
provided for in the Particular Specifications or upon the approval of the Engineer, the concrete may be
placed before constructing the stone masonry.
(i) Stone masonry constructed prior to placing concrete

Hooked steel anchors consisting of 12 mm bars each bent into an elongated letter “S” shall be
spaced 600 mm apart both horizontally and vertically unless closer spacing is shown on the Drawings
or ordered in writing by the Engineer.
To improve the bond between the stone masonry and the concrete backing, the back of the former
shall be made as uneven as the stones will permit.
Each anchor shall be rigidly embedded in a horizontal joint of the masonry with one end 50 mm from
the faces of the stones. The other end shall project approximately 250 mm into the concrete backing.
When the stone facing has been laid and the mortar has attained sufficient strength, all surfaces
against which concrete is to be placed shall be cleaned carefully; and all dirt, loose material, and
accumulations of mortar dropping, removed. Picks, scrapers, and wire brooms shall be used for this
purpose if necessary. If compressed air is available on the site, it shall be used to blow out the dust
and dirt. Water shall be dashed forcibly against the stones and into the joints. Use of a stream from a
hose is preferable for this purpose.
In depositing concrete, the top surface immediately adjacent to the stones shall be held slightly low
and a neat cement grout of the consistency of cream shall be carried on top of the concrete and
against the masonry at all times, so that the entire exposed areas of all the stones are coated with
grout.
All interstices of the masonry shall be filled and the concrete thoroughly spaded and worked until it is
brought into intimate contact with every part of the back of the masonry.
(ii) Concrete Placed before constructing masonry

Except where otherwise shown on the Drawings, a thickness of 200 mm shall be allowed for facing.
Galvanized metal slots with anchors for the stone work, or other approved type of metal anchor, shall
be set vertically in the concrete face at a horizontal spacing of not to exceed 600 mm.
The slots shall have a temporary filling of felt or other material to prevent them from being filled with
concrete.
During the setting of the stone facing, the metal anchors shall be fitted tightly in the slots at an average
vertical spacing of 600 mm. The Engineer will mark on the concrete backing the approximate location
of the anchors, and the anchor shall be placed in the stone joint nearest to the mark. At least 25% of

the metal anchors shall have a short right-angle bend to engage a recess to be cut into the stone. The
anchors shall extend to within 80 mm of the exposed face of the stonework.
Where the shape of the concrete face is unsuitable for the use of metal slots, ties consisting of
AASHTO Standard Gauge No. 9 galvanized iron wire shall be placed as directed by the Engineer; but
there shall be no less than one wire-tie for each 0.15 square metre of exposed stone surface.
In laying the stone, the concrete face shall be kept continuously wet for 2 hours preceding the placing
of the stone; and all spaces between the stone and concrete shall be thoroughly filled with mortar.
Immediately after laying, all exposed stone surfaces shall be cleaned and kept clean of loose mortar
and cement stains.
(j) Pointing
The pointing or finishing of joints shall be as shown on the Drawings or as otherwise indicated by the
Engineer.
When raked joints are called for, all mortar in exposed face joints and beds shall be raked out squarely
to the depth noted on the Drawings. Stone faces in the joints shall be cleaned free of mortar.
When weather joints are called for, the beds shall be weather struck. The joints shall be slightly raked
to conform to the bed weather joint and in no case shall the mortar be flush with the faces of the
stones.
The mortar in joints on top surfaces shall be crowned slightly at the centre of the masonry to provide
drainage.
This sub-clause also applies to re-pointing in extension work or in the repair of the existing masonry
work. Cracks in the masonry of the existing bridges and culverts shall be repaired as follows:
 Deteriorated and loose mortar particles, dirt and other undesirable materials shall be raked
free and loose stones shall be chopped out.
 The joints shall be cleaned by wire brushing, sandblasting, or by other acceptable means, to
the full depth of deteriorated mortar but in no case less than 75 mm.
 Voids and cavities which are encountered shall be cleaned.
 The surface texture of the exposed faces shall not be damaged.
 The joints shall be dampened and filled completely with cement mortar, packed solidly into the
joints and voids.
 The masonry shall be kept damp during the repointing operations.
 The masonry joints shall be finished to match the existing mortar joints and the stone work left
clean and free of mortar droppings.
(k) Plastering of Masonry Walls

Where shown on the Drawings or called for by the Engineer, the Contractor shall plaster the surface
with cement mortar, consisting of one part cement to three parts of sand by volume to a minimum
thickness of 12 mm of plaster unless otherwise instructed by the Engineer.
(l) Weep Holes

All walls and abutments shall be provided with weep holes.
Unless otherwise shown on the Drawings or directed by the Engineer, the weep holes shall be placed
at the lowest points where free outlets can be obtained and shall be spaced not more than three (3)
metres centre to centre (c/c).

Weep holes can be square, rectangular or circular in opening.
Alternatively, 100 mm diameter PVC circular pipe of appropriate length can be used. In this case, the
provision of 3 m spacing c/c is replaced by 1.5 m c/c spacing which shall be both horizontally and
vertically.
A 60 cm thick filter layer as per Table 3107/1 shall be provided unless otherwise shown in the contract.
A permeable filter material in accordance with clause 3402(g) shall be provided at the rear face of
weep holes all as shown on the Drawings or as directed by the Engineer.
(m) Cleaning Exposed Faces

Immediately after being laid, and while the mortar is fresh, all face stone shall be thoroughly cleaned of
mortar stains and shall be kept clean until the work is completed.
If ordered by the Engineer, the surface of the masonry shall be cleaned using wire brushes and an
approved acid before final acceptance.
(n) Weather Limitations

No placing of stone shall be done in freezing weather except by written permission from the Engineer
and then only by the use of such precautionary methods as may be prescribed for doing the work and
protecting it at all times. Such permission, and the use of the methods prescribed, shall not release the
Contractor from his obligation to build a satisfactory structure.
All work damaged by cold weather shall be removed and replaced.
In hot or dry weather the masonry shall be satisfactorily protected from the sun and shall be cleaned
using wire brushes and an approved acid if necessary.

Item 89.01 Stone masonry walls:

(a) Plain packed stone masonry walls (Class of masonry described) ............cubic metre (m³)
(b) Cement-mortared stone masonry walls (Class of masonry described) .....cubic metre (m³)
The quantity to be paid for shall be the number of cubic metres of stone masonry of the various
classes, complete in place and accepted.
When shown as a separate pay item in the Bill of Quantities, separate measurement shall be made for
that portion of any class of masonry contained in a specifically designated part of the structure.
In computing the volume for payment, the dimensions used shall be those determined by the payment
lines or payment volumes shown on the Drawings or ordered in writing by the Engineer.
The computed volumes shall not include any concrete or stone masonry paid for under any other item.
One-half of the volume of the mortar joint between different classes of stone masonry will be included
in the measurement for each adjoining class of masonry. The projections of face stones extending
beyond the pitch lines will not be included. The volumes of stones labelled on the plans as "cap
stones" shall be their actual volumes.
No deductions will be made for weep holes, drain pipe, or other openings of less than 0.2 square
metres or for chamfers or other ornamental cuts that amounts to 5% or less of the volume of the stone
in which they occur.

The tendered rate for each type of stonewall shall include full compensation for furnishing all materials;
trimming the areas; placing the stones and cement-mortared masonry where necessary; and all other
work necessary for completing the walls in accordance with the specifications.
The quantities of concrete; reinforcing steel; excavation of foundation trenches; and other contract pay
items which constitute the completed and accepted structure shall be measured for payment in the
manner prescribed.
The quantity, determined as provided above, shall be paid for at the contract price per unit of
measurement, respectively, for each of the particular pay items listed, that is shown in the Bill of
Quantities, which price and payment shall be full compensation for furnishing and placing all materials
including mortar; and for all labour, tools equipment, and incidental necessary to complete the work
prescribed in this and other Divisions
Item 89.02 Plastering of Stone Masonry Walls .............................................. square metre (m²)
The quantity to be paid shall be the square metre of wall completed in place and accepted.
The tendered rate shall include full compensation for furnishing all materials, removal of deleterious
materials; ensuring a clean surface; mixing and placing the plaster; and all other work necessary for
completing the work.

Division 81000: Mechanically Stabilised Earth
81001 Scope
This section covers the design and construction of mechanically stabilised earth (MSE) structures. In
broad terms this consists of a fill material with horizontal layers of reinforcing elements which may take
the form of sheets, grids, meshes, strips, bars, rods etc. The reinforcing elements, which are either
metallic or polymeric, are capable of sustaining tensile loads and the effects of deformation developed
in the fill. The outer, clad face of the fill may consist of concrete, welded wire mesh or steel. Soft,
wrap-around facing can also be used if appropriate.
All cladding, soil reinforcement and fastener materials shall be sourced from a single MSE supplier
who will be responsible for the internal stability of the structure, designed in accordance with the latest
edition of BS 8006. The MSE supplier shall have suitable professional indemnity insurance cover.
The Engineer assumes overall responsibility for the structure regarding foundation analysis and design
criteria.
The system tendered shall be the system built. No substitution will be allowed. All mechanically
stabilized earth structures shall be constructed in accordance with the approved drawings for the
proposed system.
81002 Materials
(a) Concrete Panels

Concrete panels shall be manufactured from materials which comply with the relevant requirements of
the latest edition of BS 8006. The panels may be manufactured from either un-reinforced or reinforced
concrete. The panels should be positively attached to the reinforcements. The panels should be
flexible enough to accommodate at least 1.5% differential settlement over the length of the structure
and 0.5% internal settlement of the MSE mass.
(b) Steel panels

Steel panels shall be manufactured from materials which comply with the relevant requirements of the
latest edition of BS 8006.
(c) Welded wire mesh panels

Welded wire mesh panels shall be manufactured from materials which comply with the relevant
requirements of the latest edition of BS 8006. In order to ensure the durability of the cladding the wire
diameter should have a diameter of at least 8mm
(d) Metallic soil reinforcements

Metallic soil reinforcement shall be made from materials having a certain resistance to corrosion when
buried and may take the form of sheets, grids, meshes, strips, bars, rods, ladders etc. and shall
comply with the latest edition of BS 8006. The reinforcements should have an elongation before failure
of at least 15%.
Galvanizing shall comply with the requirements of BS 729 for bars and BS 2569.
(e) Fasteners between the facing and reinforcing elements

The fasteners between the facing and the reinforcing elements shall comply with section 6.4 of the
latest edition of BS 8006

(f) Polymeric soil reinforcements and joints

Polymeric soil reinforcements and joints shall comply with section 6.2.3 and section 6.2.4 of the latest
edition of BS 8006.
(g) Accessory proprietary products

Any accessory proprietary products, elements or fittings necessary for the construction of the MSE
structure shall comply with the appropriate, accepted standards or specifications.
(h) Fill material in MSE structures

The fill material in the MSE structure shall comply with the greater requirements of either Section 6.1
of the latest edition of BS 8006 or the requirements of the supplier of the MSE wall system.
81003 Manufacturing and Handling the Cladding Panels
(a) Concrete panels

Concrete panels shall be manufactured in accordance with the dimensions and details shown on the
Drawings, and where necessary these details shall be adapted to suit joining onto existing structures,
inclined foundations, varying heights or other similar conditions.
The date of manufacture and the classification of every panel shall be clearly marked on the panel.
The concrete panels may be removed from the mould once the concrete has attained a cube
compressive strength of 7MPa. The panels shall be stacked according to the supplier’s
recommendations.
(b) Steel panels

Steel panels shall be manufactured in accordance with the dimensions and details shown on the
Drawings. The panels shall be handled in accordance with the supplier’s recommendations.
(c) Welded wire mesh panels

Welded wire mesh panels shall be manufactured in accordance with the dimensions and details
shown on the Drawings. The panels shall be handled in accordance with the supplier’s
recommendations.
(d) Accessories
Any accessory proprietary products, elements or fittings shall be manufactured in accordance with the
dimensions and details shown on the Drawings. The accessories shall be handled in accordance with
the supplier’s recommendations.
81004 Construction
(a) Foundation
The foundation plane for the MSE structure shall be graded for a width equal to the length of soil
reinforcement and to the heights shown on the drawings, and compacted to a minimum of 90%
modified AASHTO density in accordance with the requirements of these specifications. All foundation
soils found to be unsuitable shall be removed and replaced with compacted, approved granular
material. Measurement and payment for this work will be paid for under the relevant items of the
earthworks section of these specifications.
Where specified a concrete levelling course, conforming to the correct line and level, shall be provided
in accordance with the details shown on the Drawings, or as may be directed by the Engineer.

(b) Construction of the MSE structure

The construction of the MSE structure shall conform to the procedures specified by the MSE suppliers.
All the necessary safety precautions shall be strictly adhered to.
The bottom row of cladding panels shall be carefully aligned on the foundation footing in accordance
with the details provided. These panels shall be properly braced to prevent movement during the
placing of the first layers of fill. Each cladding panel shall be individually checked after having been
placed to confirm that the panel is correctly aligned within the stipulated tolerance.
The fill material behind the cladding panels shall be placed and compacted in accordance with the
provisions of the relevant section of these Specifications to at least 93% modified AASHTO density,
except that the layer thickness may vary slightly to suit the position of the soil reinforcement. The fill
should be deposited, spread, levelled and compacted in horizontal layers of appropriate thickness.
The deposition and compaction should be carried out so that all layers of soil reinforcing elements are
fixed at the specified levels on top of compacted fill.
The fill should be placed such that it slopes away from the face to ensure that rainwater is kept away
from the face of the MSE structure during construction.
The deposition, spreading, levelling and compaction of the fill should be carried out generally in a
direction parallel to the facing and should be executed in stages to alternate with the placing and fixing
of the reinforcing elements and facing. Fill shall not be placed right up to the cladding panels before
the underlying reinforcing has been covered, for sufficient length from the centre of the fill, with
compacted earth so as to anchor the reinforcement adequately to keep the cladding panel in position.
The filling shall be made from the end of the reinforcement to the cladding panels.
Care should be taken to ensure that the reinforcing elements are not damaged or displaced beyond
the specified tolerance during the process of filling and compacting. Filling should be arranged so that
no track machines run on the reinforcing elements. All vehicles and construction equipment weighing
more than 1500 kg should be kept at least 2 m away from the cladding. Suitable compaction
equipment weighing less than 1500 kg can be used within 2 m of the cladding.
(c) Fabricating and construction tolerances:

 Individual concrete panels:
o Surface regularity: When tested with a 1.5 m straight-edge, the deviation shall not
exceed 5 mm.
o Leading dimensions shall not exceed ± 5 mm
 Completed concrete cladding walls:
o When tested with a 3 m straight-edge, the deviation shall not exceed 20 mm.
o No point of the structure shall be out of position horizontally by more than 50mm.
81005 Quality Assurance
(a) General
The quality of the various materials covered in this section of the Specifications must be monitored
and the results recorded to ensure that they comply with the requirements of the latest edition of BS
8006. The standards given on the wall system supplier’s drawings need to be checked for compliance.

(b) Cladding panels

The quality of the various cladding panels covered in this section of the specifications must be
monitored to ensure that they comply with the requirements of the latest edition of BS 8006. All results
should be recorded for quality assurance purposes.
(c) Soil reinforcement

The quality of the applicable soil reinforcement must be monitored to ensure that they comply with the
relevant requirements of the latest edition of BS 8006. All results should be recorded for quality
assurance purposes.
(d) Fill in MSE

The frequency of sampling backfill material and compaction density shall be in accordance with the
requirements of the earthworks section of these Specifications. The fill shall be tested to see that it
meets the requirements relating to shear strength, chemical characteristics, durability and hydraulic
requirements.
Fill material properties are covered in the latest edition of BS 8006. Refer to any other specific
requirements that the MSE service provider may prescribe. All results should be recorded for quality
assurance purposes.
(e) Materials and components not covered in the specifications

Refer to the provisions of the latest edition of BS 8006 for testing procedures not covered in these
specifications.
81006 Design Check

A design check shall be carried out by the Engineer and shall include:
 The geometry of the structures established from the drawings and cross sections of the
proposed works.
 The stability of the foundation soils under the weight of the surcharge (dead and live load),
and the factor of safety for potential failure along slide planes or surfaces external to the MSE
structure.
 The design criteria and specifications applicable to the MSE structure.
The Contractor carries overall responsibility to the Employer for the structure including foundation
analysis.
The Engineer shall approve all the relevant MSE drawings before construction of any MSE structure
commences.
Item 810.01 Supply and erection of MSE structure

(a) Structure as shown on the Drawings (Type, cladding and reinforcement indicated) ............
................................................................................................................ square metre (m²)
(b) Additional structures as appropriate and shown on the Drawings (Type, cladding and
reinforcement indicated) ......................................................................... square metre (m²)
The unit of measurement shall be the square metre face of the MSE material supplied and erected as
shown on the Drawings. The quantity shall be calculated from the dimensions of the front face of the
structure including embedment and the surface area of nominal panel joint openings and cladding
penetrations such as pipes and other utilities.
The tendered rate shall include full compensation for all materials in the structure as supplied by the
MSE system supplier and shall include but not be restricted to:
 Technical assistance costs;

 Storing, loading, transporting and off-loading;
 Quality Assurance;
 Surface preparation for bedding and cladding panels;
 All labour, materials, formwork and construction equipment necessary for the erecting the
MSE structure complete and to the specifications;
 Excavation for concrete footings as specified in Division 8100 except that no additional
excavation shall be measured where formwork is required;
 Concrete footings for structures in accordance with the net approved dimensions for the
concrete footings and including the specified concrete class and strength;
 The installation of jointing materials, the connecting of soil reinforcement to the cladding
panels, the installation of monitoring test strip samples and settlement and tolerance
monitoring;
 Infill concrete to the specified class and strength placed on top of the wall in accordance with
the supplier’s detail;
 Supply and installation of precast concrete coping units, including any required concrete
backing, steel reinforcement or a soft-board bond breaker;
 Rockfill behind the welded mesh cladding panels;
 Synthetic fibre filter fabric.
Item 810.02 Extra over standard fill items for the construction of fills with soil reinforcement
.......................................................................................................................................
........................................................................................................... cubic metre (m³)
The unit of measurement shall be the cubic metre of fill placed between the soil reinforcement in
accordance with the approved dimensions of the reinforced soil bounded by the reinforcement.
The tendered rate shall include full compensation for the additional cost of sourcing and constructing
the fills containing reinforcement, and for adjustment to normal backfilling methods as may be
necessary for placing backfill materials as specified in this Division.

Division 81100: Construction Tolerances for Structures
81101 Scope
This Division covers the requirements with regard to the construction tolerances applicable to the
various structures and structural elements.
In the event of a discrepancy between the requirements of this Division and tolerances specified
elsewhere in the Specifications, the requirements of this Division shall take precedence.
81102 Definitions
Except were otherwise specified the following aspects of construction to which tolerances apply shall
have the following meanings attributed to them.
(a) Position
The position of a structure or structural element shall be the horizontal position of its centreline(s)
and/or centre-point(s) in relation to the overall setting out of the Works as shown on the Drawings.
(b) Alignment
The alignment of a structure or structural element shall be the alignment of its centreline(s) in relation
to the overall setting out of the Works as shown on the Drawings. Deviation from true alignment shall
be measured in degrees of an arc.
(c) Leading and Cross Sectional Dimensions

The leading and cross-sectional dimensions of a structure or structural element shall be the
dimensions relating to width, length, height, thickness, etc. which collectively determine its shape as
shown on the Drawings. Dimensional tolerances not relating to leading or cross sectional elements
shall be shown on the Drawings.
(d) Levels
The level of any structure or structural element shall be the level of the upper or lower surface as may
be relevant with reference to an established datum level on site.
(e) Surface Regularity

Surface regularity is the shape of a surface with reference to a 3m straight edge (or template in the
case of curved surfaces) placed on the surface.
The tolerance on surface regularity is expressed as a distance by which the surface tested may
deviate from a straight edge (or template in the case of curved surfaces) held against the surface.
81103 Tolerances
The tolerances given in Table 81103/1 to Table 81103/14 shall be the maximum permissible deviations
from the specified dimensions, levels, alignment, positions, etc. as shown on the Drawings of the
structures or structural elements.

(a) Foundations
Table 81103/1: Piles

Item Tolerance
1. Position 0.167 times the diameter of the pile, or 100mm, whichever is greater
2. External dimensions
2.1 Prefabricated piles + 25mm to - 5 mm
2.2 Cast in-situ piles + not specified to - 0 mm
3. Pile head level:
3.1 Average level of trimmed/cut
pile head + 25 mm to - 25 mm
3.2 Verticality or rake 1.5%
4. Straightness: For the precast piles the permissible maximum deviation from straight is
5 mm for piles up to 3 m long and 1 mm more for each additional metre
of pile length.
Table 81103/2: Caissons:
Item Tolerance
1. Position of top of caisson 150 mm
2. Verticality 1.5%
3.Dimensions:
3.1 Wall thickness + 25 mm to - 5 mm
3.2 Outer dimension of circular, rectangular or square cross-section + 25 mm to - 25 mm
4. Level: Upper level of trimmed/cut caisson head levels
4.1 Maximum deviation of average level + 25 mm to - 25 mm
4.2 Maximum deviation any individual level + 50 mm to - 50 mm
5. Foundation fill :
5.1 Average level top of fill + 25 mm/ - 25 mm
Table 81103/3: Footings, pile caps, caisson cover slabs, etc
Item Tolerance
1. Position 15 mm
2.Alignment:
2.1 Alignment of individual elements 5°
2.2 Alignment of elements as they collectively determine alignment
of structure as a whole 1 minute
3. Dimensions:
3.1 Leading dimensions in plan +25mm to - 25 mm
3.2 Thickness +25mm to - 15 mm
4. Level: Average level of slabs, footings, etc + 25 mm to - 25 mm

Table 81103/4: Columns, walls, pier, abutments, etc
Item Tolerance
1. Position 10 mm
2.Alignment:
2.1 Alignment of walls, piers, abutments and of column groups 2 minute
3. Dimensions:
3.2 Thickness of walls, piers and abutments and cross sectional +25mm to - 25 mm
dimensions of columns: + 25mm to - 3% of the specified
dimensions within the range 5 mm
to 25 mm
4. Levels: Average levels of finished or trimmed/cut columns, + 10 mm to - 10 mm
piers, walls, abutments etc.
5.Verticality:
5.1Using ordinary formwork 1 in 400: Maximum 25mm
5.2 Using sliding formwork 1 in 200: Maximum 50mm.
6. Surface regularity:
6.1Using ordinary formwork 3 mm
6.2 Using sliding formwork 6 mm
Table 81103/5: Bridge and Culvert Superstructure

Item Tolerance
1. Position 10 mm
2.Alignment:
2.1 Alignment Superstructure as a whole 1 minute
3. Dimensions:
3.1 Leading dimension in plan +25mm to - 25 mm
3.2Thickness of slabs, width and depth of beams +15mm to - 3% of the specified dimensions within the
range 5 mm to 15 mm
4. Surface regularity: 3 mm
(all elements other than upper surface of deck)
(b) Precast Beams

The following tolerances shall apply to pre-cast beams in addition to the requirements stated in sub-
Clause 81103 for superstructures.
The width of the gap between contiguous beams shall not exceed twice the specified nominal gap
shown on the Drawings or the nominal gap plus 40 mm, whichever is the lesser and the overall width
between the outer most beams on the bridge deck shall be within 40 mm of the specified width.
Table 81103/6: Precast Beam Tolerances

Item Tolerance
1. Straightness or bow: The deviation from the intended
line measured on the overall length of the beam or part
thereof shall not exceed the following:
1.1 In the horizontal plane 0.5 mm per metre length of the beam within the
tolerance range of 6 mm to 15 mm.
1.2 In the vertical plane

1.2.a I-beams 2 mm per metre length of the beam within the
1.2.b Other beams 1 mm per metre length of the beam within the
2. Camber:
2.1 The soffits of adjacent beams when placed side by Shall not at any place differ by more than 2 mm per
side on the bridge deck: metre length of the beam within the tolerance range
of 6 mm to 20 mm.
2.2 The lengths of precast beams before stressing + 0.1% of the total length within the tolerance
range of + 5 mm to + 20 mm.
3. Surface regularity: 3 mm

(c) Precast Beams and Panels
Table 81103/7: Members Other Than Flat Panels:

Item Tolerance
1. Cross-section
1.1 overall dimensions - less than 600 mm; ± 3 mm
1.2 not less than 600 mm, but less than 150 mm; ± 6 mm
1.3 not less than 1500 mm + 10 mm to -6 mm
2. Cross-section, dimension of sections such as webs, ribs and
flanges:
2.1 less than 1500 mm; ± 6 mm
2.2 not less than 1500 mm +10 mm to -6 mm
3.Length, critical dimensions of abutting members. + 0 to -6 mm

4. Length, non-critical -
4.1less than 6 m; 2 x length/1000
4.2 not less than 6 m. 6 mm
5. Twist. 10 mm/m width per 3 m of length
Table 81103/8: All Units
Item Tolerance
1. Straightness of edges and flatness of surfaces. Length/1000
2. Warp
2.1 up to 5 m diagonal; 6 mm
2.2 over 5 m diagonal. 10 mm
3. Squareness of corners -
3.1 up to 2 m on shorter side; 3 mm
3.2 over 2 m, up to 4 m, 5 mm
3.3 over 4 m. 6 mm
4. Holes or openings and the like, diameter or side
dimensions. 3 mm
5. Location of holes or openings 7 mm
6. Grooves, width and depth. 2 mm
7. Position of individual connecting bolts, bolt holes, With 3 mm of their true positions in the group
projecting metal or other devices in any associated in which they are cast.
grout (eg the joint of two precast units).
8. Longitudinal locations of any such groups (mentioned Within 6 mm of its true position in the unit in
in item (7)) which it is cast, if the tolerance does not
adversely affect the proper assembly of the
whole structure.
(d) Precast Pre-stressed Concrete Structural Elements

The length, cross sectional dimensions and straightness of all precast pre-stressed concrete structural
elements for determining compliance with these requirements shall be taken at 28 ± 2 days after the
stress has been applied.

Table 81103/9: Cross Sectional Dimensions and Straightness
Item Tolerance
1. Length
1.1 Up to 3 m ± 6 mm
1.2 3 to 4.5 m ± 9 mm
1.3 4.5 to 6 m ± 12 mm
1.4 Additional for every subsequent 1 m ± 1 mm
2. Cross section (each direction)-
2.1 up to 500mm ± 6 mm
2.2 500 to 750mm ± 9 mm
2.3 Additional for every subsequent 250mm ± 3 mm
3. Straightness or bow (deviation from intended line).
3.1 Up to 3 m 6 mm
3.2 3 to 6 m 9 mm
3.3 6 to 12 m 12 mm
3.4 Additional for every subsequent 1 m 1 mm
(e) Reinforcing Steel
Except for the requirements given hereunder no tolerances are given for the placing and fixing of
reinforcing steel. Steel shall, however, be neatly and accurately fixed in a manner that is consistent
with proper workmanship and the structural integrity of the member. Specifically the following
requirements shall apply:
(i) Tension Steel

The actual position of tension steel shall not deviate from the true position by an amount that would
reduce the effective lever arm by more than 2% of the overall depth of the member or 10 mm,
whichever is the greater.
(ii) Concrete Cover

The concrete cover to reinforcing steel shall nowhere be less than the specified cover.
(iii) Spacing between Bars

The spacing between closely spaced parallel bars, especially in beams and columns, shall, unless
otherwise detailed, not be less than the maximum size of aggregate used in the concrete.
(iv) Bending of Reinforcement

The requirement of ACI 315 regarding dimensional tolerances for the cutting and bending of
reinforcing steel shall apply with the proviso that the other requirements stated in this clause must be
met even if the tolerances in ACI 315 are not exceeded.
(f) Pre-stressing
Pre-stressing tendons shall be placed and maintained in position within the following tolerances:
Table 81103/10: Pre-stressing Tendons Tolerance

Item Tolerance
1. In the direction of the width of the member
1.1 For members of up to 200 mm in depth + 20 mm
1.2 For members exceeding 200 mm in depth + 10
2. In the direction of the depth of the member
2.1 For members of up to 200 mm in depth + 0.025 x depth
2.2 For members exceeding 200 mm in depth + 0.010 x depth within the tolerance range of + 5 mm
to + 25 mm

(g) Bridge Bearings
Table 81103/11: Bridge Bearing Tolerance

Item Tolerance
1. Position and level: Within 5mm of the position shown on the Drawings
and within 2 mm of the required level.
2. Dimensional tolerance elastomeric bearings
2.1Overall plan dimensions  3mm - 2mm
2.2Thickness of individual elastomeric layers  10%
2.3Overall thickness bearing pad  2%
2.4 Variation of one major surface out of parallel with 1.5mm
other major surfaces
Table 81103/12: Fabrication and Assembly Tolerances for Structural Steel

Item Tolerance
1. General
1.1 Fabrication and assembly tolerances on all + 2 mm.
dimensions for structural steel
1.2 Holes for fasteners of up to 25 mm in 2 mm larger than the diameter of the fastener and holes for
diameter larger fasteners not more than 3 mm larger than the diameter
of the fastener.
2. Cross section The tolerances cross sectional dimensions of rolled sections
shall be as specified in BS 4 or BS 4848 as appropriate.
3. Straightness
3.1 For compression members and beams 1/1000 of the length between the points which are laterally
(other than purlins and sheeting rails). restrained
3.2 For other members 1/500 of Overall length but not more than 25 mm
4. Length
4.1 For compression members faced at both + 1 mm
ends for bearing.
4.2 For other members + 0, - 4 mm
5. Bearing surfaces
Where two steel surfaces are required to be in shall not exceed 1 mm when the members in contact are
contact in bearing the maximum clearance aligned.
between the bearing surfaces
6.Accuracy of erection
Steelwork shall not be out of plumb over any by more than 5 mm or 1/1000 of the distance whichever is
vertical distance greater.
(h) Concrete Pavement Slab and Segmental Block Paving

The work described in this sub-section shall be constructed to the tolerances given in this Sub-clause.
(i) Level and Grade

The finished surface of completed paving shall be within ± 10mm of design level at all points. The lot
shall be deemed to comply with the requirements specified for surface levels if at least 90% of the
level measurements are within ± 15 mm of the specified levels.
The level on the finished surface of the road base for road pavements to be overlain with segmental
paving shall be trimmed within + 10mm or - 0mm of design levels.
Hangs of grade both longitudinally and transversely shall be eased over to avoid protuberance of
adjoining units.
The minimum length of ease shall be 3 unit lengths. Subject to easing constraints, the surface shall
not deviate more than 5mm from a 3 metre straight edge.
Sand bedding material shall not be used as a levelling material to compensate for base finishing
outside the above tolerances.

Paving abutting a gutter to which it drains shall be laid to a finish 4 - 6mm above the edge of the
gutter. Other paving edges shall be laid to finish within -0mm to +2mm of the level of abutting paving
or structures.
The difference in level (lipping) between adjacent paving units shall not be more than 2mm.
The finished surface of the base material shall drain freely without ponding.
Isolated spots, where the surface levels deviate by more than 20 mm of the specified levels shall be
repaired to bring the deviation to within the ± 15 mm tolerance.
Deviation from the specified longitudinal grade due to variations from level shall not exceed the
maximum variations shown in Table 81103/13.
Table 81103/13: Allowable Deviations from Grade

Length of Grade Measured in Maximum Variation from
Metres Specified Grade (%)
2 0.34
5 0.27
10 0.21
20 0.13
30 0.08
(ii) Width of Pavement and the Position of Pavement Edges

The average width of each pavement shall be at least equal to the specified width; and the edge of the
pavement shall not deviate by more than 25 mm from the specified position.
(iii) Joints
Transverse joints shall be installed within the tolerances given in Clause 7112.
Longitudinal joints shall be installed within the tolerances given in Clause 7113.
The tolerance for the groove width of sawn joints shall be ± 0.5 mm.
(iv) Thickness
The lot will be considered to comply with the requirements for layer thickness if:
 At least 90% of all the thickness measurements taken before any thickness repairs are made
is equal to or greater than the specified thickness, minus 14 mm;
 The mean layer thickness of the lot is not less than the specified thickness, minus 0.5 mm
 Isolated spots where the actual thickness is 18 mm or more, less than the specified thickness,
shall be repaired so as to fall within the 14 mm tolerance.
The thickness of the slab shall be determined by accurate levelling in the same positions at random
selected points before and after construction of the slab, and also by measuring cores drilled from the
slab (an average of 4 measurements per core).
(v) Cross Section

When tested with a 3 m straightedge placed at right angles to the road centreline, the surface shall not
deviate from the bottom of the straightedge by more than 6 mm.
(vi) Surface Regularity

When tested with a rolling straightedge, the number of surface irregularities in excess of 3 mm shall
not exceed any of the following:
 Average number of surface irregularities per 100 m taken over 300 – 600 m sections: 5
 Number of surface irregularities taken over a 100 m section: 8
 The maximum value of any individual irregularity when measured with the rolling straight-edge
or a 3 m straightedge laid parallel to the road centreline: < 7 mm
(vii) Dowels
Dowels shall be positioned within the tolerances given in Clause 7115(b).
Random checks of the dowels shall be ordered by the Engineer by taking cores at the position of the
bar ends.
(viii) Joint Sealers

Dimensional tolerances for preformed self-expanding cork joint sealer in the unexpanded state shall
be ± 1.5 mm in width and ± 3.0 mm in depth.
(ix) Sub-base
The level of the sub-base bedding layer shall not deviate by more than 5 mm above or 10 mm below
the specified level.
The surface of the sub-base bedding layer shall not deviate by more than 10 mm from a 3 m
straightedge or 10 mm in 3 m from the true vertical curve on vertical curves.
(x) Kerbs and Inverts

Finished concrete shall be within 10 mm of the specified alignment and level, at all points.
The relative deviation of any two points on the surface from their true position shall not exceed 5 mrn
in 3 m.
Deviation on vertical curves shall not exceed 5 mm in 3 m from the true vertical curve. These
tolerances are subject to the non-accumulation of water at any point.
(xi) Footways and Paving

Footways and paving shall be within 25 mm of the specified alignment and level at all points.
The finished surface shall be free from abrupt irregularities.
The relative deviation of any two points on the surface from their true position shall not exceed 3 mm
or 1 in 270 of the distance between them, whichever is the greater. These tolerances are subject to the
non-accumulation of water at any point.
(xii) Mower Strips and Edging

Finished concrete shall be within 25 mm of the specified alignment and level at all points. The finished
surface shall be free from abrupt irregularities.
(i) Miscellaneous
(i) Chamfers
Fillets used to form chamfers shall be made of hardwood, plastic or metal to a tolerance of 1 mm in
cross-sectional dimensions and the actual chamfer on the concrete shall not vary by more than 3 mm
from the specified dimensions.
(ii) Kerbs, Copings, Footways, Bridge Railings, Parapets, Guard rails, etc.
The elements shall be constructed to the specified dimensions within a tolerance of ± 5 mm on any
dimension.
The alignment shall not deviate from the true alignment by more than 10 mm in any place nor shall the
alignment deviate by more than 5 mm from the true alignment over any length of 5 m.
(iii) Natural Stone, Precast and In-situ Concrete, and Asphalt Kerbs
Natural stone, precast and in-situ concrete and asphalt kerbs shall be constructed to the lines and
levels shown in the contract to within the tolerances given in Table 81103/14.

Table 81103/14: Construction Tolerances for Kerbs
Tolerances
Type of Kerb 1 1 2
Alignment Level Straightness
Natural stone ± 25 mm ± 10 mm Max.10 mm.in 3 m
Precast concrete ± 25 mm ± 10 mm Max.10 mm.in 3 m
In-situ concrete ± 25 mm ± 10 mm Max.10 mm.in 3 m
Asphalt ± 50 mm ± 5 mm Max.20 mm.in 3 m
1
Relative to design line and level
Maximum deviation measured horizontally and vertically relative to a 3m straightedge.
2
In addition to complying with the requirements of Table 81103/14 there shall be no difference in
alignment between the ends of individual elements of natural stone or precast concrete kerbs of more
than 3mm.
(iv) Metal Beam Guardrails

Metal beam guardrails shall be constructed in the positions shown in the contract within the following
tolerances:-
 Alignment
The installed position of guardrails shall not depart from the design alignment by more than ± 30mm
nor deviate from the straight or required radius by more ± 15mm. in any 10m length.
 Height
Except for ramps, the beams shall be erected at the design height above the edge of the nearest
adjacent carriageway, or, if the guardrail is located more than 1.5m from the edge of the carriageway,
above the level of the surface vertically beneath the beam, within a tolerance of ± 30mm.

Series 9000: Ancillary Works
TABLE OF CONTENTS
DIVISION 9100: GABIONS AND M ATTRESSES .......................................................................................... 686
9101 Scope ........................................................................................................................................ 686
9102 Materials for Gabions ................................................................................................................ 686
(a) Rock ..............................................................................................................................................686
(b) Wire ...............................................................................................................................................686
(c) Galvanizing ...................................................................................................................................686
(d) Wire Mesh and Clip Fasteners.......................................................................................................687
(e) Gabions using PVC Coated Wire ..................................................................................................687
(f) Geotextile Filter Fabric .................................................................................................................687
9103 Construction of Gabion and Mattress Cages ............................................................................ 688
(a) General ..........................................................................................................................................688
(b) Selvedges.......................................................................................................................................688
(c) Diaphragms and End-Panels .........................................................................................................689
(d) Binding and Connecting Wire .......................................................................................................689
(e) Tolerances .....................................................................................................................................689
(f) Unit Weight Requirements and Test .............................................................................................. 689
9104 Construction of Gabions ........................................................................................................... 689
(a) Preparation of the Foundation and Surface for Bedding ............................................................... 689
(b) Assembly .......................................................................................................................................689
(c) Rock filling of Boxes in Retaining Walls ...................................................................................... 690
9105 Construction of Mattresses ....................................................................................................... 690
(a) General ..........................................................................................................................................690
(b) Anchors .........................................................................................................................................690
(i) Anchor Plates ............................................................................................................................................ 690
(ii) Anchor Pickets .......................................................................................................................................... 690
(c) Assembling, Positioning and Joining Mattresses ..........................................................................690
(i) Proprietary Wire Mattresses ...................................................................................................................... 690
(ii) Non-Proprietary Wire Mattresses .............................................................................................................. 690

(d) Forming Shapes ............................................................................................................................ 691
(e) Tensioning of Mattresses .............................................................................................................. 691
(f) Rock Filling .................................................................................................................................. 691
(g) Closing Mattresses ........................................................................................................................ 691
DIVISION 9200: DELINEATORS, M ARKERS AND KILOMETRE POSTS ......................................................... 693
9201 Scope ........................................................................................................................................ 693
9202 Materials ................................................................................................................................... 693
(a) Flexible Delineators, Markers, and Kilometres Posts ................................................................... 693
(i) Ground Mounted ....................................................................................................................................... 693
(ii) Guide Rail Mounted ................................................................................................................................. 693
(iii) Barrier Kerb Mounted............................................................................................................................... 693
(iv) Composition.............................................................................................................................................. 693
(v) Colour ....................................................................................................................................................... 693
(vi) Impact Resistance ..................................................................................................................................... 693
(vii) Heat Resistance .............................................................................................................................. 693
(viii) Cold Resistance .............................................................................................................................. 694
(ix) Weather Resistance ................................................................................................................................... 694
(x) Installation ................................................................................................................................................ 694
(xi) Depth Indicator Mark ............................................................................................................................... 694
(xii) Mowability ..................................................................................................................................... 694
(xiii) Sampling Rate ................................................................................................................................ 694
(b) Concrete Posts ............................................................................................................................... 694
(i) Concrete .................................................................................................................................................... 694
(ii) Paint .......................................................................................................................................................... 694
9203 Manufacturing: Concrete Posts ................................................................................................ 694
9204 Spacing of Posts ....................................................................................................................... 695
9205 Erection ..................................................................................................................................... 695
(a) Ground Mounted Flexible Units ................................................................................................... 695
(b) Guide Rail Mounted Flexible Units .............................................................................................. 695
(c) Barrier Kerb Mounted Flexible Units ........................................................................................... 695
(d) Concrete Posts ............................................................................................................................... 695
9206 Road Appurtenances ................................................................................................................ 696

DIVISION 9300: GUARDRAILS ................................................................................................................ 697
9301 Scope ........................................................................................................................................ 697
9302 Materials.................................................................................................................................... 697
(a) Guardrails ......................................................................................................................................697
(b) Guardrail Posts .............................................................................................................................. 697
9303 Erection ..................................................................................................................................... 698
9304 Requirements ............................................................................................................................ 698
DIVISION 9400: ROAD SIGNS................................................................................................................. 700
9401 Scope ........................................................................................................................................ 700
9402 Materials.................................................................................................................................... 700
(a) Structural Steel .............................................................................................................................. 700
(b) Aluminium ....................................................................................................................................700
(c) Bolts, Nuts and Rivets ...................................................................................................................700
(d) Steel Plate ......................................................................................................................................701
(e) Particle Board ................................................................................................................................ 701
(f) Concrete ........................................................................................................................................701
(g) Fibreglass ......................................................................................................................................701
(h) Retro-Reflective Material ..............................................................................................................701
(i) Paint ..............................................................................................................................................702
(j) Corrosion Protection Tape .............................................................................................................702
9403 Manufacturing of Road Sign Faces and Supports .................................................................... 702
(a) Road Sign Faces ............................................................................................................................ 702
(b) Welding .........................................................................................................................................702
(c) Aluminium Extrusions ..................................................................................................................702
(d) Galvanizing ...................................................................................................................................702
9404 Painting ..................................................................................................................................... 703
(a) Colours, Symbols and Legend .......................................................................................................703
(b) Preparation of Surfaces and Application of Paint ..........................................................................703
(c) Time of Painting ............................................................................................................................ 703
(d) Painting of concrete ....................................................................................................................... 703
(i) Surface preparation ................................................................................................................................... 703
(ii) Sealing and priming .................................................................................................................................. 703
(iii) Undercoat and finishing ............................................................................................................................ 703

9405 Storage and Handling ............................................................................................................... 703
9406 Erection of Road Signs ............................................................................................................. 704
(a) Position ......................................................................................................................................... 704
(b) Excavation and Backfilling ........................................................................................................... 704
(c) Erection ......................................................................................................................................... 704
(d) Field Welding ................................................................................................................................ 704
(e) On Site Painting ............................................................................................................................ 704
(f) Time of Erection ........................................................................................................................... 704
9408 Dismantling, Storing and Re-Erecting Existing Road Signs ..................................................... 704
DIVISION 9500: ROAD TRAFFIC M ARKINGS, ROAD STUDS AND TRAFFIC CALMING .................................. 707
9501 Scope ........................................................................................................................................ 707
9502 Materials ................................................................................................................................... 707
(a) Road-Marking Paint ...................................................................................................................... 707
(b) Retro-reflective road-marking paint .............................................................................................. 707
(c) Thermoplastic road-marking material ........................................................................................... 707
(d) Colour ........................................................................................................................................... 707
(i) Marking .................................................................................................................................................... 707
(ii) Beads ........................................................................................................................................................ 707
9503 Weather Limitations .................................................................................................................. 707
9504 Mechanical Equipment for Painting .......................................................................................... 707
9505 Surface Preparation .................................................................................................................. 708
9506 Setting Out of Road Traffic Markings ........................................................................................ 708
9507 Application of Paint ................................................................................................................... 708
9508 Application of Retro-Reflective Beads ...................................................................................... 709
9509 Road Studs ............................................................................................................................... 709
9510 Traffic Calming .......................................................................................................................... 709
(a) Speed Bumps (or humps) .............................................................................................................. 709
(i) Dimensions and Spacing........................................................................................................................... 709
(ii) Types and Construction of Speed Bumps ................................................................................................. 710
(iii) Warning Signs ........................................................................................................................................... 710
(b) Rumble Strips................................................................................................................................ 710
(i) Dimensions and Spading .......................................................................................................................... 710
(ii) Type and Construction of Rumble strips................................................................................................... 711

(iii) Warning Signs ........................................................................................................................................... 711
9511 Tolerance Requirements ........................................................................................................... 711
(a) Width ............................................................................................................................................. 711
(b) Position.......................................................................................................................................... 711
(c) Alignment of Markings ................................................................................................................. 711
(d) Broken Lines ................................................................................................................................. 711
9512 General ..................................................................................................................................... 711
9513 Faulty Workmanship or Materials ............................................................................................. 712
9514 Protection .................................................................................................................................. 712
DIVISION 9600: LANDSCAPING AND GRASSING ...................................................................................... 714
9601 Scope ........................................................................................................................................ 714
9602 Materials.................................................................................................................................... 714
(a) Fertilizer ........................................................................................................................................714
(b) Grass Cuttings ............................................................................................................................... 714
(c) Grass Seed .....................................................................................................................................714
(d) Topsoil ...........................................................................................................................................714
9603 Landscaping the Areas ............................................................................................................. 715
(a) Shaping ..........................................................................................................................................715
(b) Trimming .......................................................................................................................................715
9604 Preparation of Areas for Grassing ............................................................................................ 715
9605 Grassing .................................................................................................................................... 715
(a) Scope .............................................................................................................................................715
(b) Planting of Grass Cuttings .............................................................................................................716
(c) Seeding ..........................................................................................................................................716
(d) Top-soiling only ............................................................................................................................ 716
(e) The grassing of borrow pits, temporary deviations, camp sites, access roads and stockpile sites .716
(f) Hydro-seeding ............................................................................................................................... 717
9606 Establishment and Maintenance of the Grass .......................................................................... 717
(a) Watering, Weeding, Cutting and Replanting .................................................................................717
(b) Acceptable Cover .......................................................................................................................... 717
(c) Defects Liability Period for Grass .................................................................................................717
9607 General ..................................................................................................................................... 717
(a) Time of Planting ............................................................................................................................ 717

(b) Traffic on Grassed Areas ............................................................................................................... 718
(c) Erosion Control ............................................................................................................................. 718
(d) Responsibility for Establishing an Acceptable Cover ................................................................... 718
DIVISION 9700: PAINTING OF STEEL ...................................................................................................... 720
9701 Scope ........................................................................................................................................ 720
9702 General. .................................................................................................................................... 720
(a) Specifications ................................................................................................................................ 720
(b) Paint formula ................................................................................................................................. 720
(i) Formula A-3-71: Red Lead Sealing Paste ................................................................................................. 720
(ii) Formula A-4-90: Phenolic Red Lead Primer ............................................................................................ 720
(iii) Formula A-5-61: Vinyl Pre-treatment ....................................................................................................... 721
(iv) Formula A-6-86: Zinc Oust Zinc Oxide Primer ........................................................................................ 721
(v) Formula A-9-73: Galvanizing Repair Paint-High Zinc Dust Content ....................................................... 721
(vi) Formula A-1 0-83: Vinyl Read Lead Primer ............................................................................................. 721
(vii) Formula B-4-90 Phenolic First Field Coat for Steel ...................................................................... 721
(viii) Formula B-7-70: First Field Coal for Steel (Basic Lead Silico Chromate) .................................... 721
9703 Surface Preparation-General Requirements ............................................................................ 721
9704 Surface Preparation-Materials and Methods ............................................................................ 721
(a) Abrading on site ............................................................................................................................ 721
(b) Wet Cleaning on Site ..................................................................................................................... 722
(c) Dry Cleaning on Site ..................................................................................................................... 722
(d) Dry Blast Cleaning on Site ............................................................................................................ 722
9705 Treatment Procedures for Mechanical Damage or other Surface Defects .............................. 722
9706 Treatment Procedures for Local Failures in Protective Coatings ............................................. 722
9707 Workmanship Standards for the Surface Preparation of Steel ................................................ 722
9708 Paint and Similar Protective Coatings ...................................................................................... 723
9709 Storage Requirements and Retention Periods for Paints ........................................................ 723
9710 Application of Paint ................................................................................................................... 724
(a) General .......................................................................................................................................... 724
(b) Film Thickness .............................................................................................................................. 724
(c) Stripe Coats. .................................................................................................................................. 724
(d) Exposure Times for Prepared Steel Surfaces and Over-coating Times for Paints. ........................ 725
9711 Procedure Trials........................................................................................................................ 725

DIVISION 9800: FENCING ...................................................................................................................... 726
9801 Scope ........................................................................................................................................ 726
9802 Materials.................................................................................................................................... 726
(a) Posts, strays, standards and droppers ............................................................................................ 726
(b) Bolts for strays .............................................................................................................................. 726
(c) Barbed wire ...................................................................................................................................726
(d) Gates..............................................................................................................................................726
(e) Timber posts ..................................................................................................................................726
(f) Manufacturing tolerances for wire ................................................................................................ 726
9803 Types of Fencing ....................................................................................................................... 727
9804 Protection of Livestock .............................................................................................................. 727
9805 Clearing of Fence Line .............................................................................................................. 727
9806 Installing Posts and Standards ................................................................................................. 727
9807 Installing Wire ........................................................................................................................... 728
9808 Closing Openings under Fences .............................................................................................. 728
9809 Existing Fences ......................................................................................................................... 728
9810 Installing Gates ......................................................................................................................... 729
9811 General Requirements .............................................................................................................. 729
DIVISION 9900: FOOTWAYS AND M ASONRY AND CONCRETE SAFETY BARRIERS .................................... 731
9901 Scope ........................................................................................................................................ 731
9902 Footway..................................................................................................................................... 731
(a) Materials ........................................................................................................................................731
(b) Construction Operations ................................................................................................................731
9903 Masonry Safety Barriers ........................................................................................................... 731
9904 Precast Concrete Safety Barriers ............................................................................................. 731
9905 Measurement for Payment........................................................................................................ 732

List of Tables
Table 9102/1: Rock size ...................................................................................................................... 686
Table 9102/2: Coating of wire .............................................................................................................. 686
Table 9102/3: Mesh size ...................................................................................................................... 687
Table 9102/4: Physical Requirements for Geotextile .......................................................................... 688
Table 9103/1: Standard sizes of boxes and mattresses ..................................................................... 688
Table 9402/1: Specifications for Bolts, Nuts and Rivets ...................................................................... 700
Table 9402/2: Mechanical and Physical Properties of Fibreglass Reinforced Panels ........................ 701
Table 9509/1: Speed Bump Dimensions and Spacings ...................................................................... 710
Table 9509/2: Classification and Spacing of Rumble Strips ................................................................. 711
Table 9702/1: Formula A-3-71: Red Lead Sealing Paste .................................................................... 720
Table 9802/1: Tolerances for Wire ....................................................................................................... 727

Division 9100: Gabions and Mattresses
9101 Scope
This Division covers the material and construction requirements for gabion walls and mattresses used
in aprons for retaining walls, lining of channels, revetments, and other anti-erosion structures in
accordance with the Drawings or as ordered by the Engineer.
9102 Materials for Gabions
(a) Rock
Stones or rock for filling gabions shall be obtained from sources located by the Contractor and
Rocks used as filling for cages shall be clean, hard, sound, durable and un-weathered boulders or
rock fragments.
No rock particles shall exceed the maximum size given in Table 9102/1 and at least 85% of the rocks
shall have a size equal to or above minimum size given in the table.
Table 9102/1: Rock size
Depth of cage (mm) Minimum (mm) Maximum (mm)

0.2 75* or 95** 125
0.3 100 200
0.5 100 250
1.0 100 300
* Using 60 x 80 mm mesh
**Using 80 x 100 mm mesh
(b) Wire
All wire used in the fabrication of the gabions and in the wire operations during construction shall be to
ASTM A 910, Grade # 1010 or 1015, having a tensile strength of not less than 350 MPa.
Cold drawn steel wire fabric shall meet the requirements of AASHTO M-55.
(c) Galvanizing
All wire used in the fabrication of gabions shall be galvanized in accordance with the provisions of
ASTM A 641 with Class 3 coating or aluminised with a coating weight as per ASTM A 809 for Class A
heavy galvanized mild steel wire.
The minimum mass of the zinc- coating shall be according to the figures shown in Table 9102/2.
Table 9102/2: Coating of wire
Nominal diameter of coated wire Mass of coating

2
(mm) (g/m surface area)
3.7-4.0 290
3.0-3.6 275
2.2-2.9 260
below 2.2 245

The adhesion of the zinc coating to the wire shall be such that when the wire is wrapped six turns
round a mandrel of four times the diameter of the wire, it shall not flake or crack to such an extent that
any zinc can be removed by rubbing with bare fingers.
(d) Wire Mesh and Clip Fasteners

Wire mesh shall be hexagonal-woven mesh wherein the joints are formed by twisting each pair of
wires through three half turns.
The tightness of the twisted joints shall be such that a force of not less than 1.7 kN is required when
pulling on one wire in order to separate it from the other wire provided each wire is prevented from
turning; and the applied forces and the wire are all kept in the same plane.
The diameter of the wire and the size of mesh used shall be as shown in Table 9102/3.
Table 9102/3: Mesh size

Depth of gabion (m) Mesh size (mm) Wire diameter (mm)
80x100 2.5
0.5 and over
100x120 2.7
80x100 2.2
0.2 -0.3
60x80 2.0
The shorter dimensions of the mesh shall be taken from centre to centre of the twisted joints, and the
larger dimensions shall be between the inside ends of twisted joints.
Alternatively; wire used in the body of the mesh shall not be thinner than 11-gauge for galvanized
baskets and 12-gauge for PVC coated baskets. Selvage wire shall not be less than 10 gauge, and
lacing and tie wire shall not be thinner than 13-gauge.
Clip fasteners shall be galvanized and/or PVC coated as required and may be of any type that
provides positive lock when installed. They shall be stronger than the mesh to which they are
attached.
Galvanizing on the steel clips shall be in accordance with ASTM A 641 with a Class 3 coating, and
aluminizing shall be in accordance with ASTM A 809.
(e) Gabions using PVC Coated Wire

When gabions using PVC coated wire is specified, the wire used for the gabion mesh, and for wiring
the gabions during construction shall be galvanized wire as specified in Clause 9102(b) onto which is
extruded a polyvinylchloride (PVC) coating.
The average thickness of the PVC coating shall be as specified, either 0.30 mm for use in mildly
corrosive conditions or 0.55 mm for use in marine and other severely corrosive or abrasive conditions.
The minimum thickness of the coatings shall be 0.25 mm and 0.4 mm respectively, and the coatings
shall be capable of resisting the deleterious effects of natural weather and salt-water exposure.
The PVC coated gabions shall be of a proven brand and the brand shall be subject to the Engineer's
approval.
(f) Geotextile Filter Fabric

Where indicated on the Drawings or ordered by the Engineer, one layer of approved geotextile
material shall be placed on the prepared surface prior to the placing of gabions.
The material shall be placed as directed in vertical strips with a minimum overlap of 300 mm, and shall
be properly fastened to prevent any movement or slipping during the placing of gabions.

The geotextile shall meet the requirements given in Table 9102/4.
Table 9102/4: Physical Requirements for Geotextile

(1)
Property Test Method Units Specifications
ASTM
Grab Strength D 4632 N 1400/900
Sewn Seam Strength D 4632 N 1260/810
Tear Strength D 4533 N 500/350
Puncture Strength D 4833 N 500/3500
Burst Strength D 3786 kPa 3500/1700

-1
Permittivity D 4491 s 0.02
(2)
Apparent Size Opening D 4791 mm 0.60
(3)
Ultraviolet Stability D 4355 % 50%
(1)
The first values apply to geotextiles that break at <50 per cent elongation (ASTM D 4632). The second values apply to
geotextiles that break at >/=50 per cent elongation (ASTM D 4632).
(2)
Maximum average rolls value.
(3)
After 500 hours of exposure
9103 Construction of Gabion and Mattress Cages
(a) General
Gabions shall consist of woven steel mesh boxes or mattresses filled with stones.
Gabion panels shall be either proprietary manufacture or woven on site as described in the Contract.
Gabion cages shall be fabricated of wire mesh of the size and type and selvedge as specified below.
The cages shall be sub- divided into cells by wire mesh diaphragms and will be of two types:
 Boxes, which are generally used for the construction of gabion walls and are sub-divided into
cells by diaphragms spaced at 1.0 m intervals;
 Mattresses, in which the maximum width shall be 2.0 m; and the maximum depth shall be
0.5 m. Mattresses shall be sub-divided by diaphragms into cells having a width of 500 mm or
1.0 m as specified.
Standard sizes of boxes and mattresses are given in Table 9103/1.
Table 9103/1: Standard sizes of boxes and mattresses
Dimensions Boxes Mattresses:

Lengths: 1,2,3,4 and 6 metres 6m
Widths: 1m 2m
Depths: 0.3 m, 0.5 m, and 1.0 m 0.2 m, 0.3 m, and 0.5 m
Diaphragm spacing: 1.0 metre 500 mm or 1.0 m as directed
Other gabions may be supplied, provided there is prior approval by the Engineer.
(b) Selvedges
The cut edges of all mesh used in the construction of gabions, except the bottom edge of diaphragms
and end panels, shall be selvedged with wire of at least twice the diameter of the mesh wire diameter.
Where the selvedge is not woven integrally with the mesh but has to be fastened to the cut ends of the
mesh, it must be attached by binding the cut ends of the mesh about it so that a force of not less than
8.5 kN applied in the same plane as the mesh, at a point on the selvedge of a mesh sample 1 m long,
is required to separate it from the mesh.
(c) Diaphragms and End-Panels

The diaphragms and end-panels shall be selvedged on the top and vertical sides only.
The end-panels shall be attached by twisting the cut ends of the mesh wires at the bottom of the panel
about the selvedge on the base of the gabion. Similarly, the diaphragms shall be attached by twisting
the cut ends of the mesh to the twisted joints of the mesh of the base of the gabion. In each case the
force required to separate the panels from the base shall not be less than that required to break the
mesh over the same length.
(d) Binding and Connecting Wire

Sufficient binding and connecting wire must be supplied with the gabion cages to perform all the wiring
operations to be carried out in the construction of the gabion work specified in Clause 9104 below.
The diameter of wire shall be 2.0 mm.
(e) Tolerances
A tolerance on the specified diameters of all wire of 2% shall be permitted.
The length of the cages is subject to a tolerance of 3% and the width of cages is subject to a tolerance
of 3% up to a maximum of 25 mm.
(f) Unit Weight Requirements and Test

The unit weight of the filled gabion basket shall be at least 1600 kg/m³. Should the unit weight be less
than 1600 kg/m³, the gabion will be rejected.
The Contractor shall conduct unit weight tests to prove the density of completed gabions by weighing
a selected gabion basket filled with stones.
One unit weight test shall be conducted for each 500 m³ of gabion placed.
9104 Construction of Gabions
(a) Preparation of the Foundation and Surface for Bedding

The bed, on which the gabion cages are to be laid prior to filling, shall be levelled to a depth as shown
on the Drawings or as directed by the Engineer so as to present an even surface.
If necessary, cavities between rock protrusions shall be filled with material similar to that specified in
sub-clause 9102(a).
Where required, a foundation trench along the toe of the revetment or wall shall be excavated to the
dimensions shown on the Drawings or indicated by the Engineer.
(b) Assembly
The methods of erection, stretching, aligning, wiring and filling the gabions shall generally be in
accordance with the manufacturer's instructions as approved by the Engineer but, nevertheless,
sufficient connecting wire braces shall be provided and tensioned between the vertical sides of each of
the outer visible cells to prevent the deformation of boxes as they are being filled with stone.

It is essential that the corners of gabion cages be securely wired together to provide a uniform surface
and ensure that the structure does not appear as a series of posts or panels. Consecutive courses of
boxes should be 'bonded' as in brickwork to avoid the coincidence of vertical joints.
(c) Rock filling of Boxes in Retaining Walls

Particular care shall be exercised in filling visible faces of gabion boxes where only selected stone of
adequate size shall be used and pre-packed to obtain a fair faced finish.
The filling of boxes shall be done in stages in order to prevent deformation and bulging. Boxes shall be
filled to just below the level of the wire braces after which the braces shall be twisted to provide
tension.
Care must be taken to ensure that consecutive layers of cages being filled are filled evenly to a level
surface ready to receive the next course.
9105 Construction of Mattresses
(a) General
Steel-wire mattress protection shall be constructed in the locations and in accordance with the
Drawings. The areas on which mattresses are to be positioned shall be trimmed to the shapes
specified within a tolerance of ± 50mm except where the provision of such tolerances shall not permit
the tops of mattresses to join neatly to the inverts of adjacent culverts. Trimmed surfaces shall be free
of roots, stumps, brush, rocks and like protrusions. Mattress protection shall be constructed to the
shapes and other requirements specified herein.
(b) Anchors
(i) Anchor Plates

Where specified, anchor plates and bolts shall be installed to secure mattresses to structures.
(ii) Anchor Pickets

Where specified, anchor pickets shall be employed to secure mattress protection. Such pickets shall
be installed prior to placing mattresses. The anchor pockets shall be positioned along the line of the
upstream edge of mattresses placed on stream beds and along the line of the top edge of mattresses
placed on sloped areas. Nominal spacing of pickets shall be 1 m. Where geotextiles are employed
under mattresses, neatly cut openings shall be made in the geotextile at the appropriate locations to
permit insertion of pickets. The tops of the installed pickets shall be level with the tops of the
mattresses. Pickets that cannot be driven to the full depth shall be cut off level with the tops of the
mattresses.
(c) Assembling, Positioning and Joining Mattresses
(i) Proprietary Wire Mattresses

Proprietary wire mattresses shall be assembled in accordance with the manufacturer’s drawings and
recommendations. Assembled mattresses shall be positioned empty in the locations required for the
finished work. The first row of mattresses shall be securely positioned and filled before mattresses in
other rows are placed, joined and filled.
The corners and all diaphragm points along the side of the first row of assembled mattresses shall be
tied to the anchor plates and anchor pickets prior to rock filling. Mattresses in other rows may be
positioned, joined and filled as the work requires. The joining of mattresses shall be in accordance with
the manufacturer’s recommendations.
(ii) Non-Proprietary Wire Mattresses

Lengths of chain wire mesh shall be laid out flat on the ground surface and stretched sufficiently to
remove any kinks and bends. Each length shall be sufficient to provide for the top, bottom and two
ends. The chain-wire mesh shall be positioned length-transverse to the direction of flow, leaving a top
section of the mesh to be turned over to complete the mattress.
The bottom and ends of each length of chain wire mesh shall be bound to adjacent lengths through
each individual mesh in turn. The outermost lengths of mesh shall be cut and shaped such that part of
the bottom may be folded up to form end panels of height equal to the thickness of the mattress. Wire
ties, not less than 1.6mm diameter and having sufficient length to secure the top of the mattress, shall
be provided at 500mm intervals in each direction along the bottom of the mattress.
(d) Forming Shapes

Where necessary, mattresses shall be neatly cut, folded and tied together to form mitre joints, angles,
curves, slopes and other shapes not possible using rectangular units. Surplus mesh shall be
completely cut out or folded back and neatly tied to an adjacent mattress face. Cut or folded edges of
adjacent mattresses shall be securely bound or clipped together.
(e) Tensioning of Mattresses

Unfilled, positioned mattresses shall be tensioned using a wire strainer or by winching. The stretching
apparatus shall be firmly attached to the free end of the assembled mattress. The tensioning process
shall in no way distort the mattress shape. Adjacent mattresses shall be securely bound together along
the top, bottom and sides whilst under tension.
(f) Rock Filling

Rock filling shall be placed whilst mattresses are under tension. The method of placing rock in
mattresses shall produce a dense, evenly distributed filling with minimum voids and minimum
distortion of the mattress shape. Care shall be taken to avoid damaging the mattresses and any
geotextile under the mattresses.
Tension on the mattresses shall be released only when the mattresses have sufficient rock filling to
prevent the mesh from slackening after release.
(g) Closing Mattresses

Mattresses shall be closed, and lids and top sections tied down as soon as practical after filling. Tying
of proprietary mattresses shall be in accordance with the manufacturer’s recommendations. Tying of
non-proprietary mattresses shall be carried out in a suitable manner. The top section of each mattress
shall be turned over the rock filling and securely bound to the bottom. Each top section shall be bound
to adjacent top sections through each mesh in turn. The free end and sides of the outermost top
sections shall similarly be bound to the top and side edges of the end panels.

Item 91.01 Foundation trench excavation and backfilling

(a) In solid rock (material requiring blasting) .................................................. cubic metre (m³)
(b) Excavation (common) in all other classes of material ............................... cubic metre (m³)
(c) Backfilling .................................................................................................. cubic metre (m³)
The unit of measurement shall be the cubic metre of each class of excavation and for backfilling made
in accordance with the authorised dimensions.

The tendered rate shall include excavating in each class of material; over break; trimming trenches,
compacting and consolidating backfill; and disposal of surplus material.
Item 91.02 Surface preparation for bedding .................................................. square metre (m²)
The unit of measurement for the levelling and preparation of areas to receive gabions shall be the
square metre to the neat dimensions of wall foundations, revetments, or aprons.
The tendered rate shall include preparation of foundations; and filling cavities.
Item 91.03 Gabions and Mattresses

(a) Gabion boxes (Type, size of box and mesh indicated) ..............................cubic metre (m³)
(b) Gabion mattresses (Type, depth of mattresses, mesh size an diaphragm spacing indicated)
...................................................................................................................cubic metre (m²)
The unit of measurement shall be the cubic metre of the rock-filled cages and the quantity shall be
calculated from the dimensions of the gabions and mattresses indicated on the Drawings or prescribed
by the Engineer, irrespective of any deformation or bulging of the completed units.
The tendered rate shall include procurement of materials; tying and connecting wires; loading,
transporting and off-loading; and assembling and filling of the cages.
Item 91.04 Filter fabric .................................................................................... square metre (m²)

(type and grade indicated)
The unit of measurement shall be the square metre of area covered with filter fabric placed in position.
The tendered rate shall include procurement of materials, storage, and handling; preparation of
surfaces; and laying and protection.

Division 9200: Delineators, Markers and Kilometre Posts
9201 Scope
This Division covers the supply and erection of delineators, markers (guide posts) and kilometre posts
in positions and in accordance with the dimensions as shown on the Drawings or as directed by the
Engineer.
9202 Materials
(a) Flexible Delineators, Markers, and Kilometres Posts

Flexible units shall be made of fibreglass reinforced, thermosetting, high polymer resin; an extruded
polycarbonite resin; or other materials which are resistant to ultraviolet and infrared radiation; and
which meet the following minimum physical and performance requirements.
(i) Ground Mounted

Ground mounted flexible units shall have a minimum width of 75 mm and a minimum thickness of
3 mm. The length of each unit shall be variable such that the top of the reflective area is positioned
1200 mm above the near roadway edge.
(ii) Guide Rail Mounted

Beam guide-rail-mounted flexible units shall have a minimum width of 75 mm and a minimum
thickness of 2.5 mm. Each unit shall have a variable height such that the top of the reflective area is
800  50 m (1000  50 mm for deceleration and acceleration lanes) above the near roadway edge.
The base of each unit shall be designed to mount over the I-beam spacer, or to the top of a wood,
polymer, or other type of spacer, of the beam guide rail.
(iii) Barrier Kerb Mounted

Concrete barrier kerb-mounted flexible units shall be the same as for beam guide-rail-mounted units
except that the panel shall be 90 by 90 mm with a minimum thickness of 2.5 mm. The base shall form
a “T” shape with the panel.
(iv) Composition
For ground mounted flexible units, the portion of the unit above ground shall be one component; or
shall be bonded together if it consists of two or more components. The shape of the ground mounted
unit shall be conducive to protection of the applied retro-reflective sheeting from abrasion.
The base and panel for beam guide-rail or concrete barrier kerb flexible units shall be designed to
withstand repeated impacts, after which, the panel returns to its functioning position (90º from the
plane of the roadway surface).
(v) Colour
Flexible units shall be white or opaque in colour.
(vi) Impact Resistance

Flexible units shall be self-erecting to within 10º of original upright position within 15 minutes of impact
on five separate occasions by a vehicle traveling at 90 km/hr. Tests shall be conducted at 0º, 22º, and
45º variance of the long cross-sectional axis of the unit to the perpendicular of vehicle direction. The
same unit(s) shall be used for all angle impact tests; total impacts per unit equalling 15. The re-erected
unit shall retain the original cross-section, show no evidence of shedding or splintering, and shall
retain 80% of its original retro-reflective sheeting.
(vii) Heat Resistance

A unit shall be conditioned in an oven for two (2) hours at 60 ± 2ºC. After removal from the oven, the
unit shall be bent backwards at 90º from the upright, simulating a field hit. The unit shall, without

cracking, recover to its original position within ten (10) seconds for each of three (3) bends. Testing
shall be complete within two (2) minutes. Colour shall remain unchanged.
(viii) Cold Resistance

The same units(s) tested for heat resistance shall be tested for cold resistance. The unit shall be
conditioned for 24 hours at –18ºC and then subjected to the same testing as for heat resistance. The
unit shall conform to the same recovery and colour retention standards as for heat resistance.
(ix) Weather Resistance

A unit shall be exposed to 1 000 hours of weathering in accordance with ASTM G 26 with no
significant discolouration.
(x) Installation
Ground mounted flexible units shall be capable of being driven by hand into the ground by only one
person to proper depth without damage to the unit. The unit shall remain in the position in which it is
installed. All special fittings, attachments, or special tools shall be compatible with that type of flexible
unit. The unit’s manufacturer shall provide installation instructions and make available all special tools
required for installation.
(xi) Depth Indicator Mark

A depth indicator mark shall be located on the front (reflective) face of the drivable ground mounted
flexible units at a height of 450 mm from the bottom end of the unit with a weather resistant marking
material so as to not wash off or weather away prior to unit installation.
(xii) Mowability
Ground mounted flexible units shall be capable of being mowed over in both directions a total of
twenty (20) times (ten (10) in each direction) by a standard flail mower equipped with a front-mounted
deflector and adjusted to a minimum mowing height of 75 mm, without damage. Mowable, drivable,
flexible units must fold parallel and flat to the ground so as to not deflect upward and into the flail
mower mechanism passing above and over the unit causing any damage thereto.
(xiii) Sampling Rate

Five (5) samples per lot size of approximately 10 000 to 20 000 units will be chosen at random by the
Engineer for laboratory testing.
(b) Concrete Posts
(i) Concrete
Concrete work shall be carried out in accordance with the provisions of Division 8400.
(ii) Paint
Paint for posts shall be as specified in Clause 9404.
9203 Manufacturing: Concrete Posts

Posts shall be manufactured to the dimensions shown on the Drawings, or as directed by the
Engineer. A mixture of four (4) parts concrete sand to one (1) part Portland cement shall be used.
Forms shall be smooth and have accurate dimensions. The mixture shall be placed in the forms and
vibrated on a vibrating table or by means of other approved methods. The posts shall be reinforced as
shown on the Drawings and shall have an F3 surface finish as defined in Division 8200.
The posts shall be true to shape, smooth, and without honeycombing or other blemishes.
The recess near the top of the post shall be painted with the reflecting paint specified, while the
remainder of the top half of the post shall be painted with white road marking paint.

9204 Spacing of Posts

The spacing of units shall be as shown on the Drawings or as directed by the Engineer.
9205 Erection
(a) Ground Mounted Flexible Units

Flexible units shall be driven vertically into the ground to a minimum depth of 450 mm. Units shall be
installed so that the plane face of the centre of the reflective area is at an angle of 0º with a
perpendicular to the direction of traffic.
Retro-reflective sheeting, Type IV-A as specified in ASTM D 4956, shall be pre-applied to the front
(surface facing traffic) of the unit by the manufacturer. The retro-reflective sheeting shall cover a
minimum area of 75 mm by 300 mm, beginning a maximum of 50 mm from the top of the post. The
colour shall be white when the delineator is located on the right side to the direction to traffic and shall
be yellow when the delineator is located on the left side to the direction of traffic.
(b) Guide Rail Mounted Flexible Units

Flexible units shall be mounted on the spacer of beam guide rail using either a “U” channel base on
the I-beam spacer; or a flat base attached to a wood, polymer, or other solid top spacer. The base
shall be attached to the spacer using an adhesive recommended by the manufacturer of the base and
panel. The first unit shall be placed on the beam-guide-rail end treatment, positioned so that the
reflector area is facing the direction of traffic, then subsequently every 25 m (13 sections of guide rail)
for tangent mainline roadway, and every 13.5 m (seven sections of guide rail) for curved mainline
roadways with radii less than 580 m. If a parabolic flare in the beam-guide-rail exists, the second unit
shall be placed at the end of the flared section with subsequent units spaced as stated herein. If the
distance between the ends of the beam-guide-rail is greater than 6 m on curved mainline roadways, or
12 m on tangent mainline roadways, a unit shall be installed on the last post or end treatment.
Retro-reflective sheeting, Type IV-A shall be applied to the upper portion of the flexible unit panel. The
retro-reflective sheeting shall cover a minimum area of 115 mm by 115 mm (115 mm by 230 mm for
deceleration and acceleration lanes). The colour shall be white when the delineator is located on the
right side to the direction of traffic and shall be yellow when the delineator is located on the left side to
the direction of traffic.
(c) Barrier Kerb Mounted Flexible Units

The first flexible unit shall be placed at the beginning of the concrete barrier kerb section, positioned
so that the reflector area is facing the direction of traffic, then subsequently every 24 m. If the distance
between the end of the concrete barrier kerb and the adjacent unit is greater than 12 m, a unit shall be
installed on both sides of barrier kerb openings.
Concrete barrier kerb mounted flexible units shall be attached to the side of the barrier kerb, 75 mm
from the top of the barrier, using a method recommended by the manufacturer of the unit.
Retro-reflective sheeting, Type IV-A shall be applied to the upper portion of the flexible unit panel
facing traffic and perpendicular to the top of the concrete barrier curb. The retro-reflective sheeting
shall cover an area of 90 mm by 90 mm. The colour shall be white when the delineator is located on
the right side to the direction to traffic and shall be yellow when the delineator is located on the left
side to the direction of traffic.
(d) Concrete Posts

Posts shall be erected after completion of the bituminous surfacing.

Holes shall be excavated in the shoulder and posts placed vertical and square to the road centreline.
Backfilling shall be compacted in layers not exceeding 150 mm thick right from the bottom of the hole.
Surplus excavated material shall be disposed of to spoil.
The posts shall be painted immediately after placing.
9206 Road Appurtenances

Reflective guide posts; delineators; clusters of red reflectors; two way hazard marker sign; kilometre
th
posts; and 5 kilometre post shall conform to the details shown in the Drawings and as prescribed by
the Engineer.

Item 92.01 Delineators, markers (guide posts) and kilometre posts

(a) Delineators (material) ...................................................................................... number (No)
(b) Markers (guide posts) (material) ...................................................................... number (No)
(c) Kilometre posts (material). ............................................................................... number (No)
The unit of measurement shall be the number of units supplied and erected according to the
Specifications.
The tendered rate shall include procurement of materials; transporting, handling and storage; erecting;
excavating and backfilling including disposal of surplus excavated material; and painting.

Division 9300: Guardrails
9301 Scope
This Division covers the supply, installation and maintenance of metal plate beam guardrails at
locations and in conformity with the details, dimensions and design shown on the Drawings or as
9302 Materials
(a) Guardrails
Dimensions of guardrails and terminal sections shall be as shown on the Drawings.
Guardrails shall be supplied together with all bolts, nuts, washers and fixing materials required; other
than bolts for fixing to posts.
The W-beam rail element, back-up plates, and terminal sections shall consist of 12-gauge steel
formed into a beam not less than 300 mm wide and 75 mm deep. The 150 mm channel rail and splice
plate shall be in conformance with AASHTO M 183.
Beam rail elements and terminal sections shall be galvanized in accordance with AASHTO M 180,
Class A, Type 2. Bolts, nuts, washers, plates, rods and other hardware shall be galvanized in
accordance with ASTM A 153.
OR
Guardrails shall comply with the requirements of BS 149. When galvanized guardrails are called for on
the Drawings or in the Bill of Quantities, a hot-dip galvanized zinc coating that complies with the
requirements of BS 763 for coatings on Type A1 articles shall be applied. All bolts, nuts and washers
shall have a hot-dip galvanized zinc coating that complies with the requirements of BS 763 for
coatings on Type C1 articles. Galvanized guardrails shall not be nested when stacked for storage.
(b) Guardrail Posts

Normally only concrete posts shall be used for supporting the guardrails, but under certain
circumstances, timber or box beam posts may be used. Concrete posts shall be of the type and size
shown on the Drawings; or as described in the Particular Specifications.
Box beam posts shall conform to the prevailing version of AASHTO-AGC-ARTBA A Guide to
Standardised Highway Barrier Hardware.
Timber posts shall be supplied in lengths as shown on the Drawings and shall comply with the
requirements of AASHTO M-168 or BS 457.
Posts shall have a top diameter of at least 150 mm. Posts with a top diameter up to 230 mm will be
acceptable provided that posts of widely varying diameter are not used together in the same length of
guardrail.
Posts shall be drilled and shaped as shown on the Drawings and provided with the necessary bolts,
nuts, washers and spacer posts for fixing.
Timber posts and spacer blocks shall be preserved in accordance with any method specified in AWPA
C14 or BS 4072. No cutting, drilling or shaping will be permitted subsequent to preserving. Where
cutting of posts is, however, unavoidable, the Engineer may permit that the required length be cut off
the bottom of a post provided the exposed area is subsequently treated.

Timber posts shall not exhibit excessive cracking at the ends, particularly cracks aligned at an angle of
more than 45º to the guardrail. Posts, which, in the opinion of the Engineer, exhibit a degree of
cracking that would impair their life or strength shall not be used.
9303 Erection
The holes for the posts shall be of sufficient size to permit proper setting of the posts and to allow
sufficient room for backfilling and tamping. At least 1 m of the posts shall be embedded in the ground.
The holes for the posts shall be spaced to suit the standard length of guardrail supplied. Where shown
on the Drawings or directed by the Engineer, posts shall be set at half spacing. The hole for the
concrete block at the end of a length of guardrail shall be neatly excavated and the top 120 mm shall
be shuttered.
The posts, spacer blocks (if applicable) and guardrails shall be completely erected; set true to line and
level so that the rail is at the required height above the level of the completed road shoulder; and the
lap shall be in the direction of the traffic movement. The guardrail shall be suitably braced to prevent
any movement and all bolts tightened prior to any backfilling of holes.
After the Engineer has signified his approval of the guardrails so erected, the holes shall be backfilled
with a 12:1 soil:cement mixture. The material may be either mixed by hand or mechanically and the
correct quantity of water added to ensure that the mixture is placed at or near to optimum moisture
content. The mixture shall then be placed and thoroughly rammed in layers not exceeding 100 mm
compacted thickness. The approach ends, where the guardrail has to be bent down and anchored,
shall be constructed as shown on the Drawings.
When the backfilling is complete and the bracing removed, the posts must be rigid and vertical. The
guardrail shall be true to line and level and firmly fastened to the posts. Excess excavated material
shall be disposed of as directed by the Engineer.
All guardrails shall be erected in such a way that there are no projecting ends that might interfere with
or endanger traffic. The edges and the centre of the rail element shall contact the spacer block; or the
post where no spacer blocks are used. Guardrail elements shall lap in the direction of the traffic and, if
specified, guardrails shall be provided with terminal sections which shall be lapped on the traffic face.
All splices of rail elements shall be at a post; and plate ends shall make contact through the entire
area of the splice.
Guardrails installed with non-buried, blunt ends shall employ reflective tape on the blunt end. Such
preformed reflective tape shall be furnished in 100 mm wide rolls conforming to ASTM D 4592, type 1.
9304 Requirements
The completed guardrail shall be neat, and there shall be no visible deviations from line and grade.
The posts shall be straight and vertical. The rail beam shall not be warped but shall be in a vertical
plane parallel to the road centreline, except at flared sections. The galvanized surface on the rail shall
be smooth and continuous, free from abrasions and scratches. Any damage to the surface shall be
made good at the Contractor's expense.
Guardrails not complying with the specified requirements shall be replaced or otherwise made good.


Item 93.01 Guardrails on [material] posts Galvanized ................................... linear metre (m)
The unit of measurement shall be the linear metre of guardrail as erected excluding end units and
mitre units.
The tendered rate shall include procurement of materials; transporting, handling and storage;
excavation and backfilling and disposal of surplus excavated; painting; and testing.
Item 93.02 End units and mitre units

(a) End units.......................................................................................................... number (No)
(b) Terminal return unit .......................................................................................... number (No)
The unit of measurement shall be the number of units of each type erected.
The tendered rate shall include procurement of materials; transporting, handling and storage;
excavation and backfilling and disposal of surplus excavated; painting; and testing.

Division 9400: Road Signs
9401 Scope
This Division covers the supply and erection of permanent road traffic signs alongside and over the
carriageway, ramps and crossroads at interchanges and at the locations indicated on the Drawings or
as directed by the Engineer. The signs shall be of the standard regulatory, warning and information
signs as detailed on the Drawings and shall comply with prevailing regulations except where otherwise
indicated on the Drawings.
9402 Materials
(a) Structural Steel

Structural steel shall comply with the requirements of AASHTO M-270 grade 250 or BS 4360 for the
type of steel specified or shown on the Drawings. All structural steel, including posts, shall be
galvanized in accordance with the requirements of ASTM A123 or BS 729.
Steel posts shall comply with the requirements of ASTM A499 or BS 4848 Part 2.
(b) Aluminium
Sheet Aluminium signs shall be constructed of material conforming to ASTM B 209M alloy 6061-T6 or
alloy 5052-H38
Aluminium plate shall 2.0 mm in thickness.
Aluminium posts shall be of the sizes detailed on the Drawings and shall conform to the provisions of
ASTM B221M or BS 1474 (HE.9).
(c) Bolts, Nuts and Rivets

Bolts, nuts, and washers shall be of the same material for each attachment, and meet the
specifications shown in Table 9402/1.
Table 9402/1: Specifications for Bolts, Nuts and Rivets

Item Material Specification
Aluminium ASTM B 209 2024-T4
Bolts Steel ASTM A 307
Stainless Steel ASTM F 593
Washers Steel AASHTO M-183
Stainless Steel ASTM A 240
Nuts Steel ASTM A 307
Locknuts Steel ASTM A 307
Rivets Aluminium ASTM B 209 6061-T6
Post clips Aluminium ASTM B 179 356 T-T6
Angle and z-bars Aluminium ASTM B 209 6061-T6
Straps and Mounting Brackets ASTM A 412, type 201
All steel parts shall be galvanized per ASTM A 123. Steel bolts and related hardware shall be
galvanized per ASTM 153.

Blind rivets used for fixing sign faces to square tubing framework shall be manufactured from or
coated with a material that will not cause corrosion through electrolytic action. Blind rivets used for
joining aluminium extrusions shall be hardened aluminium blind rivets.
(d) Steel Plate

Steel plate shall be 2 mm thick and comply with the requirements of ASTM A525.
Unless otherwise or shown on the Drawings, steel plate shall be galvanized in accordance with the
requirements of ASTM A525 or BS 729 (Heavy Grade).
(e) Particle Board

Particle board shall be an exterior grade timber particle board 12.7 mm thick, unless otherwise
specified or indicated on the Drawings, and consisting of a phenolated, resin-bound timber particle
core faced with a phenolated resin impregnated paper overlay, heat-bonded under high pressure to
form a homogeneous structure.
The particle board shall comply with the relevant physical requirements for Type B-B NIST
specification PS-1 or Type M board as specified in BS 5669.
(f) Concrete
Concrete shall be manufactured and placed as specified in Division 8400. Class C 20/20 concrete
shall be used for the erection of road signs, unless otherwise shown on the Drawings or directed by
the Engineer.
(g) Fibreglass
Fibreglass reinforced thermoset polyester laminate panel shall be acrylic modified and UV stabilised
for outdoor weather-ability. Fibreglass reinforced panels shall conform to the mechanical and physical
properties shown in Table 9402/2
Table 9402/2: Mechanical and Physical Properties of Fibreglass Reinforced Panels
Mechanical Property Averaged Minimum Requirement ASTM Test

Avg. Tensile Strength 69 MPa min. D638M
Avg. Tensile Modulus 8.3 GPa min. D638M
Avg. Flexural Strength 140 MPa min. D790M
Avg. Flexural Modulus 8.3 GPa min. D790M
Avg. Compression Str. 220 MPa min. D695M
Avg. Compression Mod. 9.7 GPa min. D695M
Punch Shear 90 MPa min. D732
Thickness 3.4 ± 0.1mm
Size, dimension < 3.7m ± 3mm D3841
Squareness in 3.7 m length ± 3mm D3841
Surfaces, top and bottom Smooth
R
Color, visually uniform gray, Munsel range N.7.5/ to N.8.5/
Coefficient of lineal thermal expansion 0.01m/mm/C max. D696
Impact resistance, -54 to100C 0.54 kg from 18.3 m D3841
Flame resistance 25 mm max. D635
Weather resistance, 3000 +/-100 h grade II min. D3841
(h) Retro-Reflective Material

Retro-reflective material shall be supplied in engineering-grade material which shall conform to the
requirements of ASTM D 4956.
The material shall be supplied with a pressure-sensitive or heat-applied adhesive backing protected by
a removable liner.

(i) Paint
Paints for road signs shall be as specified in SANS 1519 or selected from ERA’s list of approved road
sign paints. Project acceptance will be based on the appearance of an approved brand name on the
container label. All paints and solvents shall conform to air pollution regulations, including those for the
control (emission) of volatile organic compounds (VOC) as established by the Environmental
Protection Authority.
The paint shall be delivered to the Site in sealed containers bearing the name of the manufacturer and
the type of paint.
The viscosity of the paint shall be such that it can be applied without thinning.
(j) Corrosion Protection Tape

Corrosion protection tape used between aluminium and steel shall be "Scotchrap 50" or an equal
approved material.
9403 Manufacturing of Road Sign Faces and Supports
(a) Road Sign Faces

Road sign faces shall be manufactured in strict accordance with the details of the prevailing Traffic
(Signs) Regulations or as shown on the Drawings. They shall be manufactured from either steel plate,
aluminium plate or fibreglass according to the Particular Specifications. Wherever possible, road sign
faces shall be manufactured as one unit. Road signs that are too large to be transported as one unit
can, with the approval of the Engineer, be manufactured in sections. The completed sections shall be
assembled in the shop prior to delivery to ensure that all sections fit together properly and that the
legends are properly spaced and aligned. Joints in sign faces shall only be provided at locations and
to details approved by the Engineer. The signs shall be faced with engineering grade retro-reflective
material.
(b) Welding
All welding of steelwork shall be carried out in accordance with the standards laid down in
AASHTO/AWS D1.5 Bridge Welding Code or BS 5135. Welding shall be done before painting.
(c) Aluminium Extrusions

Aluminium extrusions for sign faces shall be joined together by blind rivets or bolts. They shall
preferably not be joined longitudinally but, if this cannot be prevented without excessive waste, they
shall be joined neatly and joints staggered. No sections shorter than 500 mm shall be used.
Where aluminium extrusions are to be faced with retro-reflective background material, it shall be pre-
applied to individual sections before assembly with the material taken around the face edges of each
extension for at least 10 mm. Retro-reflective material shall be heated to facilitate binding around
edges without damaging the material. Where possible, letters across the joint between two extrusions
should be avoided.
(d) Galvanizing
Where the galvanizing of structural steel signboard frames and signboard supporting structures is
specified, it shall be done as far as is practicable after welding. Where, however, this is not practicable,
the steel sections shall be galvanized before assembly and then welded. All welds shall be thoroughly
cleaned, loose material removed and dressed after which the welds shall be coated with two coats of
an approved zinc-rich paint.
Unless otherwise specified in the Bill of Quantities, galvanized steel posts will not require painting.
Where details for the construction of sign faces, the framework of the sign faces and the attachment
thereof to the supporting framework are not shown on the Drawings, the Contractor shall design these
himself and submit the details to the Engineer for approval before manufacture.
9404 Painting
(a) Colours, Symbols and Legend

Paint colours, symbols, legends and borders used on road signs shall comply with the regulations of
prevailing Traffic (Signs) Regulations.
The colours and shades shall conform to the colours and shades specified in the Traffic (Signs)
Regulations.
(b) Preparation of Surfaces and Application of Paint

Immediately before painting, prepare the surface according to the following:
 Clean the surface;

 Remove dirt, dust, and other contaminants from the surface using methods recommended by
the paint manufacturer;
 Thoroughly dry the surface;
 Determine that the surface temperature is between 10 and 40C;
 Determine that the surface temperature is 3C or more above the dew point according to
ASTM E337;
 Determine that the humidity is 85% or less, unless specified otherwise on the manufacturer’s
product data sheet
Unless otherwise specified, aluminium and galvanized steel road signs will not require painting.
(c) Time of Painting

Painting shall not be carried out more than six (6) months prior to erection.
(d) Painting of concrete
(i) Surface preparation

The surface of the concrete to be painted shall be cleaned of all dust, loose particles, laitance, scum,
and other deleterious materials, washed and allowed to dry.
(ii) Sealing and priming

The surface shall be sealed with an approved clear sealer and primed with primer diluted to 50%.
(iii) Undercoat and finishing

An undercoat shall be applied after priming, followed by two finishing coats of road marking paint. If
shown on the Drawings, the finishing coats shall consist of a plastic textured coating of a manufacture
approved by the Engineer, applied by means of a sponge roller.
9405 Storage and Handling

All road signs or portions of road signs shall be so handled and stored in a weather-proof storeroom to
prevent any permanent deformation or damage to painted surfaces.
All unpainted surfaces and steelwork shall be protected against corrosion.

9406 Erection of Road Signs
(a) Position
Road signs shall be erected in the positions shown on the Drawings or indicated by the Engineer.
(b) Excavation and Backfilling

Excavations for the erection of road signs shall be made according to the dimensions shown on the
Drawings. Where the excavations are to be backfilled with soil, a 1:12 cement:soil mixture shall be
made and backfilled at optimum moisture content in 100 mm thick layers and compacted to a
minimum of 90% of modified AASHTO density.
Where posts or structures are to be fixed in concrete, or where concrete footings are to be cast, the
concrete, formwork and reinforcement shall comply with the requirements of Division 8400. The holes
shall be completely filled with concrete up to the level shown on the Drawings or indicated by the
Engineer. The upper surface of the concrete shall be neatly finished with sufficient fall to ensure proper
drainage.
(c) Erection
Road signs shall be erected as shown on the Drawings or directed by the Engineer. During erection,
the structural steelwork shall be firmly bolted and protected in order that no buckling or damage is
caused during erection, or by the equipment used for erection. Posts to which road signs are to be
fixed shall be vertical, and the undersides of road signs shall be horizontal after completion of erection.
(d) Field Welding

All welding done during erection shall comply with the requirements for welding during manufacture.
(e) On Site Painting

All painting done after erection shall comply with the requirements for painting during manufacture.
The Contractor at his own cost shall make all places where the paintwork has been damaged during
erection good to the satisfaction of the Engineer.
(f) Time of Erection

Road traffic signs shall be erected immediately prior to the opening of the road to public traffic unless
otherwise decided by the Engineer.

The Contractor shall protect the completed road signs against all damage until the Employer finally
accepts it, and he shall maintain the road signs until the Maintenance Certificate is issued. Damage or
defects caused by faulty workmanship or negligence shall be made good by the Contractor at his own
cost to the satisfaction of the Engineer.
9408 Dismantling, Storing and Re-Erecting Existing Road Signs

Where ordered by the Engineer, the Contractor shall dismantle existing road signs, store them, and re-
erect them at new positions indicated. This work shall be done with as little damage as possible to the
signs.
Where required by the Engineer, the signs shall be repainted or repaired and new materials shall be
used for part or all of the supporting structure.


Item 94.01 Sign faces with painted background. Symbols, lettering and borders in
engineering grade retro-reflective material with signboard constructed from:
(Specify material and thickness)
(a) Warning and regulatory signs
i. Area not exceeding 2 m² ........................................................... square metre (m²)
ii. Area exceeding 2 m² ................................................................ square metre (m²)
(b) Information and Guide signs
i. Area not exceeding 2 m² ........................................................... square metre (m²)
ii. Area exceeding 2 m² ................................................................ square metre (m²)
The unit of measurement shall be the square metre of completed sign face surface area.
The tendered rate shall include procurement of completed sign board face; frame and fixing brackets;
painting; galvanizing; reflective lettering; symbols, legend and border; brackets, bolts, nuts, etc.; and
transporting, handling and storage.
Item 94.02 Sign supports:

(a) Concrete supports, Class C 20/20 .................................................................. number (No)
(b) Steel posts ....................................................................................................... number (No)
(c) Concrete posts ................................................................................................ number (No)
The unit of measurement for supporting structures shall be number of supports. Bolts and other
accessories shall not be measured.
The tendered rate shall include procurement of materials including all bolts, screws, and accessories;
transporting, handling and storage; excavation, backfilling and compacting and disposal of surplus
excavated material; erection; painting; and testing.
Item 94.03 Concrete in road sign footings including excavation and backfilling (class
indicated) .......................................................................................... cubic metre (m³)
Measurement and payment shall be made as specified in Division 8400.
The unit of measurement shall be the cubic metre of concrete placed measured in place according to
the neat dimensions of the footing as shown on the Drawings or directed by the Engineer.
The tendered rate shall include formwork as item coverage in Pay Item 82.01, 82.02, 82.03 and 82.04;
concrete as item coverage in Pay Item 84.01; and excavation, backfilling and compacting and disposal
of surplus excavated material.
Item 94.04 Dismantling, storing and re-erecting road signs with a surface area of:
(a) Up to 2 m² ........................................................................................................ number (No)
(b) Exceeding 2 m² ............................................................................................... number (No)
The unit of measurement shall be the number of signs dismantled, stored and re-erected in each size
group.
The tendered rate shall include dismantling and storing the road signs and supporting structures;
transporting the material to a new location; re-erecting the road signs and new bolts and nuts required
for such re-erection; restoring the location where they were dismantled; demolishing the concrete
footings of existing signs to at least 200 mm below the adjacent ground level; disposing of the
resulting debris; and cutting concrete or steel support structures at not less than 200 mm below the
adjacent ground.
Payment for excavations, and the new material and concrete required for re-erecting the road signs
shall be made under the appropriate Pay Item, and any repairs and painting which may be necessary,
shall be paid for as “extra work”.
Item 94.05 Dismantling and storing road signs with a surface area of:
(a) Up to 2 m² ........................................................................................................ number (No)
(b) Exceeding 2 m² ................................................................................................ number (No)
The unit of measurements shall be the number in each size group dismantled and stored.
The tendered rate shall include carefully dismantling and disassembling the road signs; loading,
transporting, off-loading and carefully stacking all the materials; restoring the site where the road signs
have been dismantled; demolishing the concrete footings of existing signs to at least 200 mm below
the adjacent ground level; disposing of the resulting debris at approved dumping sites; cutting
concrete or steel support structures at not less than 200 mm below the adjacent ground level.
Note:
Concrete, formwork and reinforcing steel for road sign footings shall be measured and paid for in accordance with the provisions
of sections 8200, 8300 and 8400, but such payment items shall appear under this section in the Bill of Quantities.

Division 9500: Road Traffic Markings, Road Studs and Traffic

Calming
9501 Scope
This Division covers the permanent marking of the road surface with white or yellow painted lines; or
symbols as indicated on the Drawings; or where required by the Engineer. It also covers the supply
and fixing of retro-reflective road studs.
9502 Materials
(a) Road-Marking Paint

Paint for applying road traffic markings shall be as specified in SANS 731 or selected from ERA’s
approved list of white and yellow road-marking and retro-reflective road marking paints. Project
acceptance will be based on the appearance of an approved brand name on the container label. All
paints and solvents shall conform to air pollution regulations, including those for the control (emission)
of volatile organic compounds (VOC) as established by the Environmental Protection Authority.
The paint shall be delivered to the Site in sealed containers bearing the name of the manufacturer and
the type of paint.
The viscosity of the paint shall be such that it can be applied without thinning.
(b) Retro-reflective road-marking paint

Retro-reflective road-marking paint shall comply with the requirements of sub-clause 9502(a)
(c) Thermoplastic road-marking material

Where specified in the Particular Specifications or on the Drawings, thermoplastic road-marking
material shall comply with the requirements of AASHTO M249.
(d) Colour
(i) Marking
The colour to be used shall be bright white or yellow.
(ii) Beads
Retro-reflective glass beads shall comply with AASHTO M247 Type T.
9503 Weather Limitations

Road marking paint shall not be applied to damp surfaces; or when the relative humidity exceeds 80%;
or at temperatures lower than 10ºC; or when, in the opinion of the Engineer, wind strength is such that
it may adversely affect the painting operations.
9504 Mechanical Equipment for Painting

Unless otherwise approved by the Engineer the equipment shall consist of apparatus to clean the
surfaces; a mechanical road painting machine; and all additional hand-operating equipment necessary
to complete the work. The mechanical road marking machine shall be capable of painting at least two
(2) lines simultaneously and shall apply the paint to a uniform film thickness at the rates of application
specified hereinafter. The machine shall be so designed that it will be capable of painting the traffic
markings to a uniform width with sides within the tolerances specified hereinafter, without the paint
running or splashing. The machine shall further be capable of painting lines of different widths by

adjustment to the spray jets on the machine or by means of additional equipment attached to the
machine.
9505 Surface Preparation

Traffic markings shall be applied to bituminous surfaces after sufficient time has elapsed to ensure that
damage will not be caused to the painted surface by volatile substances evaporating from the
bituminous surfacing. In no case shall traffic markings be applied until at least two (2) weeks after the
completion of the bituminous surfacing or any longer period required by the Enginee, has expired.
Before the paint is applied, the surface shall be clean and dry and completely free from any soil,
grease, oil, acid or any other material which will be detrimental to the bond between the paint and the
surface. The portions of the surface where the paint is to be applied shall be properly cleaned by
means of watering, brooming or compressed air if required.
9506 Setting Out of Road Traffic Markings

The lines, symbols, figures or marks shall be set out by means of paint spots of the same colour as the
proposed final lines and marks. These spot marks shall be at such intervals as will ensure that the
traffic markings can be accurately applied, and in no case shall they be more than 1.5 m from each
other. Normally spots of approximately 10 mm in diameter should be sufficient.
The dimensions and positions of traffic markings shall be as shown on the Drawings or as specified in
the prevailing Traffic Regulations.
After spotting, the positions of the proposed road markings such as dotted lines and starting and
finishing points of barrier lines shall be indicated on the road. The Engineer must approve the pre-
markingsprior to the commencement of any painting operations.
The positions and outlines of special markings shall be produced on the finished road in chalk and
shall be approved by the Engineer before they are painted. The use of approved templates will be
permissible on condition that the Engineer approves the positioning of the marking before painting is
commenced.
9507 Application of Paint

Paint shall be applied as figures, signs, letters, symbols, broken or unbroken lines or other marks as
shown on the Drawings, or directed by the Engineer.
Where the paint is applied by means of a machine, it shall be applied in one layer. Before the road
marking machine is used on the permanent works, the satisfactory working of the machine shall be
demonstrated on a suitable site which is not part of the permanent works. Further testing shall follow
adjustment to the machine. Only when the machine has been correctly adjusted, and the use thereof
approved by the Engineer after testing, may the machine be used on the permanent work. The
operator shall be experienced in the use of the machine.
After the machine itself has been satisfactorily adjusted, the rate of application shall be checked and
adjusted if necessary before application on a large scale is commenced.
Where two or three lines are required next to each other, the lines shall be applied simultaneously by
the same machine. The paint shall be stirred before application in accordance with the manufacturer's
instructions. Paint shall be applied without the addition of thinners. Where painting is done by hand, it
shall be applied in two layers, and the second layer shall not be applied before the first layer has dried
out sufficiently. As most road marking paint reacts with the bitumen surface of the road, the paint is to
be applied with only one (1) stroke of the brush or roller at any one point on the road.
Ordinary road marking paint shall be applied at a nominal rate of 0.42 l/m², or as directed by the
Engineer.
9508 Application of Retro-Reflective Beads

Where retro-reflective paint is required, the retro-reflective glass beads shall be applied by means of a
suitable machine immediately after the application of the paint in one continuous operation. The rate of
application of the beads shall be 0.8 kg/litre paint or such other rate as may be indicated by the
Engineer. Machines, which apply the beads by means of gravity only, shall not be used. The beads
shall be sprayed onto the paint layer.
Upon approval by the Engineer, paint rollers or brushes may be used for marking letters, symbols,
stop bars, short temporary detours or other such areas as directed by the Engineer. When rollers and
brushes are allowed, glass beads shall be applied to the wet paint film at the specified rate and in a
manner suitable to the Engineer.
9509 Road Studs

Road studs shall be of the types indicated on the Drawings and shall be fixed in the positions indicated
and approved by the Engineer.
Before fixing, the surface shall be thoroughly cleaned as specified in Clause 9505.
The studs shall be fixed to the road surface by means of an approved epoxy resin in accordance with
the manufacturer's instructions after the road lines have been completed. Sufficient adhesive shall be
used to give complete coverage of the contact area and to provide a slight excess. The road studs
shall be pressed on the prepared area and all excess adhesives pressed out. The excess adhesive
shall then immediately be removed with a suitable solvent. The studs shall be protected against impact
until the adhesive has hardened.
9510 Traffic Calming

Traffic calming measures for enforcing speed reduction shall be in the form of speed bumps or rumble
strips as shown on the Drawings or instructed by the Engineer. They shall be constructed to:
 Regulate the movement of motorised traffic on a road by reducing accidents caused by

speeding vehicles; and
 Reduce the speeds of motorised traffic at junction approaches for improved safety and to
enhance the priority order at the junction.
When constructing traffic calming measures, the Contractor shall take every precaution to ensure that
other road facilities or furniture such as drainage, pedestrian walkways and crossings, street lighting
etc are not interfered with.
(a) Speed Bumps (or humps)
(i) Dimensions and Spacing

The height, breadth and spacing of speed bumps are given in Table 9509/1. The bumps shall span the
full width of the road.

Table 9509/1: Speed Bump Dimensions and Spacings
Spacing (m)
Desired Speed (km/h) Height, h (mm) Breadth, b (mm)
(centre-to-centre)
0 - 10 150 2.0 30
11 - 25 150 3.0 40
26 - 35 100 4.0 50
36 - 45 100 4.5 60
46 - 60 100 5.0 70
In areas where pedestrian crossings are required as part of the bump, the bump shall be constructed
with a flat top with suitable painted markings. At least one bump shall be constructed on either side of
the bump used as a pedestrian crossing.
(ii) Types and Construction of Speed Bumps

Speed bumps shall be proprietary brand speed bumps installed to the requirements of the
manufacturer or bumps constructed in situ using asphaltic material.
For bumps constructed in situ, the following shall apply:
 Identify the positioning of the bumps;

 Demarcate the “core” of the bump using timber frames. The “core” shall measure 0.4 times the
required breadth of the bump as indicated in Table 9509/1 and the frame height shall be
20mm less than the required bump height.
 Asphaltic concrete as specified in Table 6403/3 shall be added between the frames and
tamped until level; after which the frames shall be removed.
 With the “core” as a guide, the rest of the bump shall be formed by adding more asphalt to
form a surface of even curvature, which, with a tamper shall give a bump height of
hmm + 10mm.
 The asphalt while still workable shall be compacted with a roller (> 0.75 tonne mass) to
achieve the required height.
 Following the setting of the asphalt the bump shall be painted on the ramp of the bump in the
direction of traffic flow with thermoplastic white reflective paint or any suitable material
(iii) Warning Signs

Wherever speed bumps are constructed retro-reflective warning signs shall be placed at a distance of
between 100m and 250 m from the bump on both approaches depending on the projected speed at
the start of the section.
(b) Rumble Strips
(i) Dimensions and Spading

The height of an individual strip shall be between 12mm and 15mm and the breadth shall be
200 ± 10mm as shown on the Drawing or as instructed by the Engineer. The length of the strip shall be
equal to the width of the road.
Rumble strips shall be constructed in sets of 4 strips with the classification and spacing as shown in
Table 9509/2 to correspond with the required speed reduction on the relevant stretch of road.

Table 9509/2: Classification and Spacing of Rumble Strips
Distance to Strip Set of next

Approach Speed of Classification of Spacing of strips
Lower Speed
Traffic (km/h) Strip Set (centre-to-centre, m)
(centre-to-centre, m)
Over 100 A 4.0 100
76 - 100 B 3.0 40
50 - 75 B 3.0 40
Less than 50 C 2.0 N/A
(ii) Type and Construction of Rumble strips

Rumble strips shall be proprietary brand speed bumps installed to the requirements of the
manufacturer or bumps constructed in situ using asphaltic material.
For strips constructed in situ, the following shall apply:
 Identify the positioning of the rumble strips.

 Ensure the road surface is reasonably level and clean.
 Demarcate individual strips using a timber frame of height 15mm with the inner edge of the
frames spaced 400mm from each other.
 Asphaltic concrete as specified in Table 6403/3 shall be added between the frames and
tamped until level; after which the frames shall be removed.
 The asphalt while still workable shall be compacted with a roller (> 0.75 tonne mass) to
achieve the required height and to round-off the edges of the strip.
(iii) Warning Signs

Wherever rumble strips are constructed retro-reflective warning signs shall be placed at a distance of
not more than 50m from the first strip in direction of approach to the strips.
9511 Tolerance Requirements

Road traffic markings shall be constructed within the tolerances shown hereinafter.
(a) Width
The width of the lines and other markings shall not deviate from the specified width by more than 5%.
(b) Position
The position of letters, figures, arrows, and other markings shall not deviate from the true position
specified by more than 20 mm.
(c) Alignment of Markings

The alignment of any edge or a longitudinal line shall not deviate from the true alignment by more than
10 mm in 15 m.
(d) Broken Lines

The length of segments of broken longitudinal lines shall not deviate from the specified length by more
than 150 mm.
9512 General
The broken lines, the length of segments and the gap between segments shall be as indicated on the
Drawings. If these lengths are altered by the Engineer, the ratio of the lengths of the painted section to
the length of the gap between painted sections shall remain the same. Lines shall not be painted more
than 3 months prior to opening of the road to public traffic.
Lines on curves, whether broken or unbroken, shall not consist of chords but shall follow the correct
radius.
9513 Faulty Workmanship or Materials

If any material not complying with the requirements is delivered on the Site or used in the Works, or if
any sub-standard work is carried out, such material or work shall be removed, replaced or repaired as
required by the Engineer at the Contractor's own cost. Rejected traffic markings and paint which has
been splashed or dripped on the surfacing, kerbs, structures or other such surfaces, shall be removed
by the Contractor at his own cost, in such a way that the markings or spilt paint will not show up again
later.
9514 Protection
After the application of paint, the traffic markings shall be protected against damage by traffic or other
causes. The Contractor is responsible for the erection, placing, and removal of all warning boards,
flags, cones, barricades, and other protective measures, which may be necessary.

Item 95.01 Paint (specify road marking, retro-reflective road marking and/or thermoplastic)
(a) White lines (broken or unbroken) (width of line indicated) ........................... kilometre (km)
(b) Yellow lines (broken or unbroken) (width of line indicated) .......................... kilometre (km)
(c) White lettering and symbols ................................................................... square metre (m²)
The unit of measurement for painting of lines is a kilometre of each specified width of line and the
quantity paid for shall be the actual length of line painted in accordance with the instructions of the
Engineer, including the length of gaps in broken lines.
The unit of measurements for lettering, symbols or traffic island markings is a square metre and the
2
quantity to be paid for is the actual surface area per square metre measured to the nearest 0.01m of
lettering, symbols or traffic markings painted in accordance with the Drawings or as directed by the
Engineer.
The tendered rate shall include procuring and furnishing of all material and equipment including the
retro-reflective beads; protection and maintenance; setting out of lettering, symbols and traffic island
markings and lines; and control of traffic.
When more than five (5) per cent but less than ten (10) per cent of road markings vary in position
more than specified in Sub-clauses 9511(b) and (c), a pay factor of 0.85 will be applied. Road
markings that fail the dimensional tolerances and are allowed to remain in place will be accepted at a
reduced contract unit price based on a pay factor of 0.75.
When paint and reflective beads are not applied at the minimum rates specified, the unit price will be
reduced by the sum of the percentages the paint and beads are deficient. Paint and beads will not be
accepted if they are applied at less than 70% of the contract requirements.

Item 95.02 Variation in rate of application:

(a) White paint................................................................................................................... litre (l)
(b) Yellow paint ................................................................................................................. litre (l)
(c) Glass beads..................................................................................................... kilogram (kg)
The unit of measurement for variation in rate of application of paint and glass beads shall be a litre
and kilogram respectively.
Payments for variations shall be made as specified in the Conditions of Contract.
Item 95.03 Road studs (type stated) ....................................................................... number (No)

The unit of measurement for road studs shall be the actual number of approved road studs placed.
The tendered rate shall include procuring materials; and fixing and maintenance.
Item 95.04 Traffic Calming:

(a) In situ asphalt Speed Bumps (dimensions and spacing specified) ................... number (No)
(b) In situ asphalt Rumble Strips (classification of set of 4 strips specified) ..... linear metre (m)
(c) Proprietary traffic calming measures (type indicated) ....................................... number (No)
The unit of measurement for cast in situ asphalt speed bumps shall the number constructed as
specified. For in situ asphalt rumble strips, the unit of measurement shall be the metre of sets of 4
rumble strips along the length of the road and constructed to the full width of the road as specified.
Any proprietary traffic calming measures indicated on the Drawings or instructed by the Engineer shall
be measured by the number of speed bumps or rumble strips supplied and installed to the
manufacturer’s specifications.
The tender rate shall include locating and positioning the traffic calming measures; furnishing,
transporting, mixing, placing and compacting of asphaltic materials; painting and signage; and any
other incidental items as indicated on the Drawings or as directed by the Engineer.

Division 9600: Landscaping and Grassing
9601 Scope
This Division covers the establishment of vegetation on cut and fill slopes; and in areas where the
natural vegetation has been cleared or covered. The establishment of vegetation should also be at
areas where materials were excavated and are likely to be eroded; and eroded areas at culvert outlets
that are potentially and actively expanding towards the road pavement.
9602 Materials
(a) Fertilizer
The type of fertilizer to be used shall be one or more of the following as approved by the Engineer:
 Urea;
 Super phosphate;
 Muriate of potash.
(b) Grass Cuttings

Grass cuttings shall be fresh cuttings of an approved type of grass with sufficient root material where
required to ensure good growth.
(c) Grass Seed

Only good quality fresh seed shall be used and the types of seed shall be as specified in the Particular
Specifications.
(d) Topsoil
Topsoil shall consist of fertile loamy soil, selected from areas showing a good coverage of natural
vegetation preferably grasses. It shall be free from deleterious matter such as large roots, stones, and
refuse, stiff or heavy clays and noxious seeds, which would adversely affect its suitability for planting
grass.
Topsoil shall be obtained wherever suitable material occurs, either in the road reserve from areas
where cuts and fills are to be constructed or from borrow areas to be cleared, as described in
Clause 4202. The Engineer shall indicate to the Contractor the requirements regarding the quantity of
topsoil required and the areas from which it shall be selected and removed. Unless otherwise
specified, topsoil shall be taken from not more than 400 mm from the surface. If the Contractor fails to
conserve topsoil as instructed, he shall obtain suitable substitute material from other sources at no
extra cost to the Employer.
Where so specified, the Contractor shall procure and furnish topsoil from his own sources outside the
Site; such sources shall be approved by the Engineer.
Topsoil shall be stockpiled in separate loose heaps as tipped from the trucks and shall not be
stockpiled higher than 3 m. Care shall be exercised to prevent the compaction in any way of topsoil,
especially by trucks travelling over such material.
The Contractor should stockpile topsoil for the reinstatement purposes of all construction sites,
including borrow pits, stockpiling sites, campsites, diversions, access roads and other sites. For these
purposes, the Contractor shall not mix the fertile topsoil with the sub-soils. To enable natural slope
protection by grassing, topsoil is required to allow the grass to grow and root.
9603 Landscaping the Areas
(a) Shaping
Areas within the road reserve but outside the road prism which require shaping by means of bulk
earthworks such as contoured areas at intersections and rest areas which require earthworks shall be
excavated, filled and compacted when required, and shaped to the correct contours to within a
tolerance of plus or minus 150 mm. Such work shall be regarded as being earthworks and
measurement and payment shall be made under Section 4000 except that quantities may be
measured by means of a grid system of levels taken at 10m intervals before and after shaping or else
it may be determined by levelled cross-sections.
(b) Trimming
Trimming shall consist of trimming the existing or previously shaped ground to an even surface with
the final levels generally following the original surface. It is a requirement that the drainage remains
effective. Trimming shall be done where instructed by the Engineer to areas inside the road reserve
but outside the road prism (ie normally outside the tops of cuts or the toes of fills) but trimming of rock
outcrops will not be required.
Trimmed surfaces shall be left slightly rough to facilitate a better binding with topsoil or the natural
establishing of vegetation.
When subsequent grassing is required or when it is ordered by the Engineer, areas previously shaped
shall be trimmed as described above to within a tolerance of plus or minus 100 mm with all
undulations following a smooth curve. The above tolerance shall apply only to areas where the final
contours are given on the Drawings.
During trimming, all stones in excess of 50 mm in size and all excess material shall be removed.
9604 Preparation of Areas for Grassing

The areas to be grassed shall be cleared of all loose stone larger than 50 mm. Where directed by the
Engineer topsoil shall be placed and shall be reduced to a fine tilth, free of loose stones larger than
100 mm.
Fertilizer shall be distributed at a rate not less than 75 gm/square metre, prior to grassing.
9605 Grassing
(a) Scope
This work shall consist of the furnishing and planting of grass on shoulders, embankment, slopes,
verges and other locations as shown on the Drawings or as indicated by the Engineer. Unless
otherwise instructed by the Engineer, the work shall be taken up as soon as possible following the
construction of the embankment, shoulders, etc. The Contractor shall plant grass at all embankments
and cut slopes which are susceptible to erosion with grass species which are multi-purpose and deep
rooting species with a good horizontal growth (eg “Vetiver Grass”); and shall ensure the survival of the
grasses to an acceptable level before handing over to the Employer. The planting of grass shall be
done during the first few days of the rainy season at all the identified erosion-prone areas.
The Contractor shall propose to the Engineer at least 28 days in advance the species and methods
intended for use in the grassing operations.
The area to be grassed shall have been previously constructed to the required grades and slopes and
cross-sections. Soil of the surface to be planted shall be loosened, freed from all stones larger than
50 mm in size; sticks; stumps; and any undesirable material. Where required, approved topsoil shall
be spread over the slopes. The spreading of topsoil shall not be done when the ground is excessively
wet. On slopes the planting shall start from the top downward. The distance between the plants shall
not be less than 150 mm unless approved by the Engineer.
For the protection of erosion prone areas, the type of grasses to be used for this purpose should be
first established. For this reason, grasses with multiple uses serving different groups should be
identified.
(b) Planting of Grass Cuttings

The areas to be planted shall, unless already damp, be thoroughly watered before planting to ensure
that soil will be uniformly wet over a depth of at least 150 mm when planting takes place.
Rooted grass cuttings or seedlings shall be evenly planted by hand in lines spaced at 1 m down the
slope. Individual plants shall be spaced at 0.25 m horizontal intervals. Only fresh plants shall be used
and grass that has been allowed to dry out shall not be used. Immediately after planting, the grass
shall be given a copious watering.
(c) Seeding
Seeding can only be carried out after seed has been harvested between the months of June and
August and allowed to lie dormant for a period of at least six (6) months. The Contractor shall make
his own arrangements for the collection of seed. The seed shall be spread on prepared ground as
defined in Clause 9604 in sufficient quantity to establish an acceptable grass cover as defined in Sub-
clause 9606(b).
(d) Top-soiling only

Where, in the opinion of the Engineer, the planting of grass or seeding can be dispensed with on
account of favourable climatic and other conditions, the Contractor may attempt to establish grass by
top-soiling only. Topsoil shall be selected for the presence of natural grass and seeds; and shall be
removed and placed whenever possible at a time that would favour the establishing of grass. These
areas shall be treated with an anti-erosion compound, if so instructed by the Engineer. Fertilizing shall
be done as specified in Clause 9604.
After the topsoil has been placed, it shall be lightly rolled and well watered with subsequent watering
and mowing whenever instructed by the Engineer.
The Contractor will not be held responsible for establishing an acceptable grass cover as defined in
sub-clause 9606(b) when this procedure is followed, but will be responsible for the consequences of
any failure to water, or mow, or weed the grass as instructed by the Engineer.
No payment for grassing shall be made other than for placing topsoil; providing and applying fertilizers
and for watering; mowing; and weeding the grass, which will be paid for at the tendered rates. For any
repairs caused by erosion; and similar work, the Contractor will be paid for as a variation in terms of
the Conditions of Contract.
(e) The grassing of borrow pits, temporary deviations, camp sites, access roads and
stockpile sites
Prior to any grassing that may be required on such areas, the finishing-off of borrow pits as described
under Clause 4304; removal of the temporary diversions and access roads; and the clearing of camp
sites as described in the Conditions of Contract, shall have been carried out as specified in the
relevant sections.

(f) Hydro-seeding
Hydro-seeding shall be carried out by a specialist sub-contractor approved by the Engineer. The sub-
contractor shall supply details of the mulch, seed and fertiliser to be applied taking into account the soil
type and climate in the project area.
9606 Establishment and Maintenance of the Grass
(a) Watering, Weeding, Cutting and Replanting

All planted areas shall be adequately watered at frequent and regular intervals in order to ensure
proper germination of seeds and growth of grass until the grass has established an acceptable cover
and, thereafter, until the end of the Defects Liability Period. The amount and frequency of watering
shall be subject to the Engineer's approval. Watering shall commence and continue as soon as the
seeds have germinated and growth begins.
Weeds shall be controlled by means of pulling, cutting or any other approved means.
All grassed areas shall have acceptable cover as defined below at both the beginning and the end of
the Defects Liability Period indicated in Sub-clause 9606(c).
Grass planting shall be carried out to the satisfaction of the Engineer and where the Engineer
considers that the grass planting to be unsatisfactory, the Engineer shall direct measures to bring the
grassing to an acceptable level. The Contractor shall water the grasses for a period not less than four
(4) weeks after the planting. Watering shall be done in such a way that no erosion occurs. Any
damage made by truck wheels shall be repaired without delay. The Contractor shall erect the
necessary warning signs and barriers if so required. Any areas failing to show a uniform growth shall
be replanted and the grass shall be maintained in a good condition until the final acceptance.
At the completion of the Contract, the grassed areas shall have a thick well-established uniform mat of
grass without bare patches and shall be free of areas with erosion.
(b) Acceptable Cover

An acceptable grass cover shall mean that not less than 90% of the area planted or seeded shall be
covered with grass and that there shall be no bare patches of more than 500 mm in maximum
dimension.
(c) Defects Liability Period for Grass

The Defects Liability Period for grass shall commence when an acceptable cover, as defined in Sub-
clause 9606(b), has been established and shall be one (1) year. This means that the Defects Liability
Period for grass can commence earlier or later than the Defects Liability Period for other portions of
the Contract.
If the Defects Liability Period for grass expires before the end of the Defects Liability Period for the
other road-works, the Contractor shall further mow the grass on such areas as instructed by the
Engineer up to the end of the Defects Liability Period for the main roadworks.
9607 General
(a) Time of Planting

The planting of grass shall be carried out as far as practicable during periods most likely to produce
beneficial results. The Contractor shall make every effort to programme his operations in such a
manner that this is done as far as possible.

(b) Traffic on Grassed Areas

The Contractor shall not plant grass until all operations that may require road building equipment to be
taken over grassed areas have been completed. No road building equipment, trucks or water-carts
shall be allowed on areas that have been grassed; and only equipment required for the preparation of
areas, application of fertilizer and spreading of topsoil will be allowed to operate on areas to be
grassed.
(c) Erosion Control

During construction, the Contractor shall protect all areas susceptible to erosion by installing all
necessary temporary and permanent drainage works as soon as possible, and by taking such other
measures as may be necessary to prevent the concentration of surface water and scouring of slopes,
banks and other areas.
Any runnels or erosion channels developing during construction or during the Defects Liability Period
shall be backfilled and consolidated and the areas restored to their proper condition. The Contractor
shall not allow erosion to develop on a large scale before effecting repairs and all erosion damage
shall be repaired as soon as possible and, in any case, not later than three months before the
termination of the Defects Liability Period. All topsoil or other material accumulated in side drains shall
be removed at the same time. Topsoil washed away shall be replaced.
(d) Responsibility for Establishing an Acceptable Cover

The Contractor shall be solely responsible for establishing an acceptable grass cover and for the cost
of replanting where acceptable cover is not obtained.
Where, however, in the opinion of the Contractor, it is doubtful from the outset if it will be possible to
establish an acceptable cover, the Contractor may inform the Engineer of the reasons; and the
Engineer shall, if he agrees, either allow the Contractor to adopt another method of grassing or agree
to accept whatever cover can be obtained, provided that all reasonable efforts are made to establish a
good cover using the method proposed.

Item 96.01 Stockpiling of Topsoil ..................................................................... cubic metre (m³)

The unit of measurement for stockpiling of topsoil shall be the cubic metre of topsoil measured at the
place of excavation on instructions from the Engineer.
The tendered rate shall include excavation; loading; haulage, and stockpiling in a condition suitable for
later use.
Item 96.02 Preparation of areas for grassing:

(a) Top-soiling ..................................................................................................cubic metre (m³)
The unit of measurement shall be the cubic metre of topsoil applied at the specified thickness or as
directed by the Engineer, measured in-situ after the topsoil has been placed. The quantity shall be
calculated from the net area of the surface topsoil multiplied by the average thickness of the topsoil.
Any topsoil placed in excess of the average thickness specified or ordered will not be measured.
The tendered rate shall include preparing the surface to be top-soiled; excavating from stockpile or
original ground; transport, offloading, placing and spreading to required thickness; levelling off to a
smooth surface; and removing any stones as specified.
(b) Provide and apply chemical fertilizers (type) ..........................................................tonne (t)
The unit of measurement of fertilizer shall be the tonne of each type of fertilizer ordered and applied.
The tendered rate shall include furnishing the fertilizer; transporting it to the point of use; spreading
and mixing it into the soil.
Item 96.03 Grassing:

(a) Planting of grass cuttings ................................................................................. hectare (ha)
The unit of measurement for planting of grass cuttings shall be the hectare.
The tendered rate shall include furnishing and planting the cuttings; watering, weeding, replanting.
Topsoiling will be paid for separately under Pay Item 96.02(a).
(b) Seeding ............................................................................................................ hectare (ha)
The unit of measurement for seeding shall be the hectare.
The tendered rate shall include furnishing the seeds; applying the seeds; watering; weeding; and
reseeding bare patches.
The following payment schedule shall apply:
 Planting of the grass or seeding to the satisfaction of the Engineer: 50%.

 Establishment of a satisfactory covering of grass to the approval of the Engineer: 50%
Item 96.04 Replacement or replanting of trees and growth management ..........Number (No)
The unit of measurement of replacement or replanting of trees shall be in numbers (No).
The tendered rate shall include full compensation for supply of trees; site preparation; planting,
watering, weeding, replanting (if necessary); and all other incidentals that may be required to establish
an acceptable cover and maintain the planted seedlings. It shall also include full compensation for all
labour, materials, plant, site preparation and other incidentals.
The tendered rate shall also include full compensation for a recorded inventory of affected tree species
including lists of all tree species with their exact numbers and pictures of the affected areas.
Item 96.05 Reinstatement of construction sites

a) Reinstatement of camp sites ...................................................................... Provisional Sum (PS)
b) Reinstatement of quarries, borrow pits, plant sites, storage sites, diversions, and access and haul
roads .........................................................................................................Provisional Sum (PS)
c) Percentage allowed for overhead and profit on item 96.05 (a) & (b) ........................ Percent (%)
The unit of measurement of reinstatement of construction sites shall be a Provisional Sum.
The Provisional Sum shall include full compensation for preservation of topsoil during establishment of
the sites; removal of selected/foreign materials, if any, and dumping them at authorised locations;
loosening compacted soils using a ripper or any other available methods; spreading the preserved
topsoil uniformly over the surface to encourage vegetation growth and agricultural production;
reshaping and providing suitable drainage to avoid stagnation of water and where necessary, as
instructed by the Engineer, erecting barriers around the sites to ensure the safety of animals and the
local people, especially children.
In addition, the Provisional Sum for camp sites shall also include full compensation for the complete
removal of buildings, including their foundations; and removal of all concrete and masonry remains
and scrap metal from workshops. Item 96.05 (a) will be applicable if camp sites and their related
facilities are to be demolished.
Division 9700: Painting of steel
9701 Scope
This Division covers the preparation of steelwork to receive protective coatings and the application of
those coatings. This applies not only to new steelwork but also to the repair of damaged coatings and
those, which are breaking down.
9702 General.
(a) Specifications
Raw materials for the paints shall conform to the requirements of the following specifications:
 Alkyd resin solution: Federal TT -R-266, Type 1 or Type II.

 Aluminium paste: ASTM D 962, Type 2, Class B
 Anti-skinning agent: Federal Test Std.No.141a Method 3021
 Barium sulphate pigment: ASTM D 602
 Basic lead silico-chromate: ASTM D1648
 Chrome oxide green: ASTM D 263
 Chrome yellow pigment and paste: ASTM 0 211, Type III
 Liquid drier: ASTM D 600
 Mineral spirits: ASTM D 235
 Raw Linseed oil: ASTM D 234
 Red iron oxide: ASTM D3721, D3722 & D3724
 Red lead pigment and paste: ASTM D 83, 97 per cent grade.
 Turpentine: ASTM D13
 Zinc oxide and paste: ASTM D 79
(b) Paint formula

All paints shall be made from materials meeting the requirements specified in 9702(a)
The formulas are stated in terms of dry pigment.
(i) Formula A-3-71: Red Lead Sealing Paste

Formula A-3-71, Red Lead Sealing Paste shall comply with Table 9702/1.
Table 9702/1: Formula A-3-71: Red Lead Sealing Paste
Red Lead (dry pigment) 88.5 %

Raw linseed oil 8.5 %
Non-leafing aluminium paste 9%
Drying time 24 hours
(ii) Formula A-4-90: Phenolic Red Lead Primer

The primer shall meet the requirements of Federal Specification TT -P-86, Type IV

(iii) Formula A-5-61: Vinyl Pre-treatment

The primer shall meet the requirements of Federal Specification MIL-P-15328B or MIL-P-15328C,
Primer Pre-treatment Formula 117B for Metals. The wash primer coat shall be spray-applied at a
2
coverage rate of 6.1 to 7.4 m /litre to yield a dry film of 0.5 to 0.9 mm thickness.
(iv) Formula A-6-86: Zinc Oust Zinc Oxide Primer

The primer shall meet the requirements of Federal Specification TT-P-641
(v) Formula A-9-73: Galvanizing Repair Paint-High Zinc Dust Content

The primer shall meet the requirements of Federal Specification MIL-P-21035
(vi) Formula A-1 0-83: Vinyl Read Lead Primer

The primer shall meet the requirements of Federal Specification MIL-P-23281
(vii) Formula B-4-90 Phenolic First Field Coat for Steel

The phenolic first field coat shall meet the requirements of Federal Specification TT -P-86, Type IV
(viii) Formula B-7-70: First Field Coal for Steel (Basic Lead Silico Chromate)
The paint shall meet the requirements of Federal Specification TT -P-615, Type Il. Other than colour,
the characteristics of the B-7-70 shall be the same as listed for A-7-70.
9703 Surface Preparation-General Requirements

The Contractor shall comply with the following requirements during surface preparation:
 Prior to blast cleaning or abrading steel surfaces, or before over-coating painted surfaces,
contamination by oil or grease shall be removed by wet cleaning the affected areas as
described in Clause 9704:
 Clean water which does not leave harmful residues on the surface shall be used for cleaning
and rinsing.
 Only cleaning agents approved by the Engineer shall be used.
 Surface preparation shall be continued until the standard described in the Contract has been
achieved.
 Weld spatter shall be removed from accessible areas, which are to be painted. Firmly
adhering weld spatter in the heat affected zone shall be removed before blast cleaning.
 Following dry surface preparation of surfaces, and before any wet cleaning, all dust and debris
shall be removed from accessible areas by sweeping and vacuum cleaning.
 Immediately before application of each coat of paint, the Contractor shall ensure that the
surfaces:
o Meet the standard of preparation described in the Contract.
o Are free from harmful residues, including dust, grit and paint degradation products.
o Are free from detrimental contamination.
o Are free from moisture detrimental to the coating to be applied.
 Coats of paint shall be free from embedded metallic or other foreign particles including
metallic dust. Deposits of adherent matter shall be cleaned off immediately they occur.
Coatings damaged in the process shall be restored.
9704 Surface Preparation-Materials and Methods
(a) Abrading on site

Any encrusted foreign matter or paint, which may be difficult to remove by abrading alone, shall with
the Engineer's approval be dislodged by scraping, aided by hand or power wire-brushing. The work
shall be completed before abrading the areas so affected.
Abrading shall be carried out using abrasive paper or other material or a flexible abrasive disc
mounted on a power- driven flexible pad. Abrading tools may be used to remove weld spatter. Wet
abrading may be employed for the preparation of finishes over sound undercoats.
A burnished appearance caused by the polishing in of paint, rust or dirt will not be acceptable.
Areas of previously corroded steel which have been prepared by abrading down to bright steel and
blast cleaned where appropriate, shall be protected by the primer before any cleaning down or
preparation of adjacent surfaces.
(b) Wet Cleaning on Site

Wet cleaning shall be carried out by scrubbing with a stiff-bristled brush using water and a cleaning
agent. Immediately after cleaning, the surfaces shall be thoroughly rinsed.
(c) Dry Cleaning on Site

Surfaces shall be cleaned by scrubbing with a dry stiff-bristled brush.
(d) Dry Blast Cleaning on Site

The Contractor shall ensure that the grade of non-metallic abrasives is adequate for the purpose
intended. Non-metallic abrasives shall not be recycled.
9705 Treatment Procedures for Mechanical Damage or other Surface Defects

Score marks and indentations in the surface of a steel substrate shall be treated by abrading or
grinding to bright steel to produce a surface without sharp edges or abrupt change in contour. Damage
to unprepared surfaces shall be treated before blast cleaning. Other surface defects in the steel
substrate, including fissures caused by the removal of 'hackles' or inclusions shall be similarly treated
subject to the approval of the Engineer.
In the case of damage to paint coatings only, surface preparation shall be by abrading or other
methods agreed with the Engineer. The paint coatings shall then be restored.
In all cases where only paint coats are to be restored, the edges of paint coatings adjacent to the
affected area shall be bevelled back into sound paint. This work shall be carried out before any final
blast cleaning.
On site, unless otherwise agreed by the Engineer, over-coating shall be started immediately after
surface preparation of the affected area and continued as soon as each coat is dry enough for over-
coating.
9706 Treatment Procedures for Local Failures in Protective Coatings

On-site paint coatings that have failed shall be restored. Abrading down to sound paint or bright steel
and blast cleaning to clean steel, 2nd quality as defined in Clause 9707 are permissible methods of
surface preparation when restoring paint systems over a steel substrate.
In all cases of local failure, the extent of the failure shall be agreed with the Engineer. Restoration of
protective coatings shall not be started until the standard of surface preparation, including the
cleanliness of the surface has been approved by the Engineer.
9707 Workmanship Standards for the Surface Preparation of Steel

The following standards of workmanship shall be applied for blast cleaning, abrading, grinding and
cleaning steel surfaces:
 Blast cleaned surfaces shall be free from sharp spikes of parent metal defined as 'rogue
peaks' formed by the impact of abrasive particles and which project above the blast cleaning
profile. Any 'rogue peaks' which in the opinion of the Engineer would be detrimental to the
protective system shall be removed.
 'Hackles' and inclusions caused by the rolling process, visible after blast cleaning, which in the
opinion of the Engineer would be detrimental to the protective system, shall be removed.
Affected surfaces shall be prepared by grinding or abrading to bright steel in accordance with
Clause 9704. Sharp edges shall be rounded.
 Steel surfaces to be prepared by any of the methods described in the Contract shall be such
that after surface preparation the surfaces shall be free from detrimental contamination.
 Surface preparation by blast cleaning shall be to one or more of the following standards of
visual cleanliness:
o 'Clean steel' 1st Quality: there shall be a blast cleaning pattern overall. The surface
profile shall be free from mill scale, rust and foreign matter when viewed through a
x10 illuminated magnifying glass of a type approved by the Engineer.
o 'Clean steel' 2nd Quality: there shall be a blast cleaning pattern overall. The surface
profile shall be free from mill scale, rust and foreign matter when viewed by normal
vision.
o 'Bare steel' (blast cleaned or abraded): the surface shall be free from all rust scale,
loose particles and mill scale.
 'Harmful Residues' or 'detrimental contamination': surfaces shall be deemed to be free
from harmful residues' or 'detrimental contamination' after surface preparation when, in the
opinion of the Engineer, any remaining matter will not reduce the required durability of the
specified protective system.
 'Bright steel': Surfaces free from defects or prepared to this standard by grinding or abrading
shall have an overall bright appearance.
9708 Paint and Similar Protective Coatings

All paints shall be supplied in sealed containers of not more than 5 litre capacity and these shall be
used in the order of delivery. Each container shall be clearly marked on the side to show the name of
the manufacturer; registered description of the material, including purpose (eg whether primer,
undercoat or finish); colour; batch number; and date of manufacture.
The Contractor shall ensure that the properties of the paints he has selected are suitable for the
conditions on site including temperature and humidity, and that he is able to apply the paints
satisfactorily to all parts of the structure in these conditions.
Unless otherwise described in the Contract, all paints forming any one protective system shall be
obtained from the same manufacturer.
9709 Storage Requirements and Retention Periods for Paints

On delivery to the site, paint shall be unloaded directly into a secure paint store. Ventilation shall be
provided as necessary to maintain the temperature of the paint store between 5ºC and 27ºC. If at any
time or place paint in tins or painters kettles is allowed to reach temperatures outside these limits, the
paint shall be discarded and not used in the Works.
Paint which has not been used within 12 months of the date of manufacture or the shelf-life
recommended by the manufacturer shall be discarded and not used in the Works.

9710 Application of Paint
(a) General
Paint shall be supplied from the Contractor's paint store to the painters ready for application. Any
adjustment of formulation shall be on approval of the Engineer. Any addition of solvent shall be made
in the store, in the presence of the Engineer, and shall not exceed 5% by volume of the paint. Paint
shall be applied only to surfaces, which have been prepared and cleaned as described in this Division.
A coat of paint in a system shall be applied by brush or approved spray system.
Paint shall not be applied under the following conditions:
 When the relative humidity rises above 90%;

 During rain, mist or in a dust laden atmosphere;
 When the amount of moisture likely to be deposited on the surface by condensation or rain
before or after painting may have a harmful effect on the paint:
 When wind borne dust may have a harmful effect on the paint.
(b) Film Thickness

The Contractor shall furnish the Engineer with details of the overall wet film thickness for each coat
proposed for application. The Contractor shall also provide information as to the total amount of paint
expected to be used for each coat of paint. The calculation of the amount of paint to be used shall be
based on the volume of solids plus an allowance for waste.
The following requirements on paint film thickness shall apply:
 Wet film thickness gauges shall be used where practicable to check that the wet film thickness
is not less than:
min 𝑑𝑟𝑦 𝑓𝑖𝑙𝑚 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑚𝑑𝑓𝑡)𝑥 100
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠 (%)
 During the application of a paint system the Contractor shall ensure that the progressive total
thickness of the applied coats will allow the specified minimum total dry film thickness of the
system to be attained without exceeding overall, the proposed wet film thickness referred to in
this Sub-clause by more than 20%.
 The local dry film thickness for any primer shall not exceed the specified mdft by more than
30% and for other paints by more than 75%.
Each coat of paint of a specified system at whatever thickness applied shall be virtually free from
surface defects, particularly crating; pin-holing; blistering; ravelling; sagging; bittiness; dry spray and
cissing. The finished system shall have an even and uniform appearance.
All successive coats in a system including the stripe coats shall be in contrasting colours to aid
identification.
(c) Stripe Coats.

Unless otherwise described in the Contract two stripe coats shall be applied to all welds and to all
external corners. The first stripe coat shall be applied over the primer or sealer, the second stripe coat,
in second or third undercoat paint, shall be applied before the last undercoat of the complete system.

(d) Exposure Times for Prepared Steel Surfaces and Over-coating Times for Paints.
Clean steel prepared by blast cleaning, or bright steel prepared by abrading or by grinding, shall be
primed within 4 hours.
Prepared steel surfaces which have been restored shall be over-coated with the primer, or first
undercoat as appropriate, before the surfaces have been affected by moisture and in any case within
4 hours.
Steel surfaces, which have been primed or sealed on site shall have the following coat applied within 7
days. The next coat shall be applied within a further 14 days, or such lesser time recommended by the
paint manufacturer.
9711 Procedure Trials

Unless otherwise described in the Contract, the Contractor shall carry out site procedure trials with the
labour and equipment to be used for the work. The trial area shall be at least 1 m². The Contractor
shall demonstrate his ability to carry out blast cleaning and to apply the paints he has selected.
Painting of the main steelwork shall not be started until procedure trials have been completed to the
satisfaction of the Engineer. Any adjustment to the paint formulation shown to be required by the trials,
other than an adjustment to the solvent, shall be agreed with the Engineer.

Item 97.01 Preparation of steelwork prior to coating

(a) Preparation of bare metal surfaces ........................................................ square metre (m²)
(b) Preparation of existing metal surfaces ................................................... square metre (m²)
The measurement shall be the net surface area in square metres to be treated.
The tendered rate shall include specimen panels demonstrating the preparation of steelwork; and
preparation, including cleaning.
Item Pay Item 97.02 Protective system to steelwork

(a) Protective system to bare metal surfaces .............................................. square metre (m²)
(b) Protective system to existing steelwork ................................................. square metre (m²)
The measurement shall be the net surface area to be treated.
The tendered rate shall include making good any damage or defect in the surface to be treated and in
the finished surface; complying with any special requirements in respect of ambient conditions for the
application of protective treatment; intervals between successive operations and applications;
preparing materials for application in accordance with the manufacturer's recommendations; painting
of steelwork under cover and everything necessary to facilitate the painting of steelwork on Site;
obtaining the correct dry film thickness of paint and providing an Elcometer to prove this to the
Engineer's satisfaction

Division 9800: Fencing
9801 Scope
This work consists of constructing fences and gates. It also covers the moving of existing fences
where necessary and the erection of new fences along the boundaries of the road reserve where so
indicated on the Drawings, or as directed by the Engineer.
It shall also include the erection and later removal of temporary fences to prevent animals straying
onto temporary diversions or onto the road itself. Except when the Engineer allows otherwise, new
fences as well as temporary fences shall be erected before construction of a particular portion of the
road commences; or before temporary diversion are open to traffic.
This Division also covers the dismantling of existing fences and the stacking of the fencing material.
9802 Materials
(a) Posts, strays, standards and droppers

Posts, strays and standards shall be of the type and size indicated on the Drawings. Wooden posts
shall comply with the requirements of AASHTO M168 or BS 1722. Timber posts shall be treated at the
Engineer's option with either creosote or copper chrome arsenate, the latter preservative not to be
used in the case of hardwoods.
(b) Bolts for strays

Bolts shall be galvanized steel bolts of the required length and diameter, which shall not be less than
12 mm. All the necessary bolts, together with nuts and washers, shall be supplied with each post.
(c) Barbed wire

Barbed wire shall comply with the requirements of AASHTO M 280 or BS 1722 and shall be mild steel
grade double strand uni-directional twist wire; each strand 2.5 mm diameter; and for use at any height
above ground. The wire shall be galvanized.
Barbs shall be manufactured from 2.0 mm (12 1/2 gauge) galvanized wire and shall be spaced at no
more than 150 mm.
(d) Gates
Gates shall be manufactured to the dimensions shown in the Drawings or specified in the Bill of
Quantities.
Gates shall be complete in every respect including hinges, washers, bolts and locking chain attached
to the gate.
(e) Timber posts

Timber posts for holding down mats where the fence crosses streams, shall comply with the
requirements AASHTO M280 or BS 1722; and shall be creosote impregnated.
(f) Manufacturing tolerances for wire

The actual diameter of wire supplied shall nowhere be less than the specified diameters by more than
the tolerances shown in Table 9802/1

Table 9802/1: Tolerances for Wire
Specified diameter Tolerance

1.0 - 1.8 mm 0.05 mm
2.0 - 2.8 mm 0.08 mm
3.15 - 4.0 mm 0.10 mm
9803 Types of Fencing

The fencing shall be erected in accordance with the dimensions shown on the Drawings.
Where existing fences have to be dismantled and re-erected, they should be re-erected either to the
same design as originally constructed with such modifications as the Engineer may require; or they
shall be erected to one of the standards specified herein, all as ordered by the Engineer.
9804 Protection of Livestock

From the time of the occupancy of the site until the date of the final maintenance certificate, the
Contractor shall take all measures necessary for the protection and control of livestock on the sections
of the properties affected by his operations. The Contractor shall provide gates in existing fences for
the purpose of access and shall ensure that all gates are kept closed during such time as they are not
actually in use by Work’s traffic.
Where alternative arrangements cannot be made the Engineer may direct the Contractor to erect
temporary fencing where necessary to protect livestock exposed to straying through his operations.
Such fencing shall be of adequate standard and shall be erected ahead of construction operations.
The fencing shall be maintained in good order during construction operations and on completion of the
work it shall be removed from Site and all surfaces restored. The Engineer may order that any
permanent fencing which is required be erected ahead of construction operations, where this is
practicable, in lieu of the erection of temporary fencing.
Payment for the protection of livestock excluding the erection of temporary fences shall be included in
the amount tendered for the Contractors Establishment on Site as specified in Division 1300.
9805 Clearing of Fence Line

The fence line shall be cleared over a width of at least 1 m on each side of the centreline of the fence
and surface irregularities shall be graded so that the fence will follow the general contour of the
ground. Clearing shall include the removal of all scrub, stumps, isolated loose boulders or stones and
other obstructions, which will interfere with proper construction of the fence. The bottom of the fence
shall be located a uniform distance above the ground line in accordance with the requirements shown
on the Drawings. All material removed shall be burnt or disposed of in disused borrow pits.
Any area outside the road reserve, where clearing is not permitted by the Owner, or is not practical,
shall not be cleared if so directed by the Engineer.
9806 Installing Posts and Standards

Straining posts shall be erected at all ends, corners, and bends in the line of fences and at all
junctions with other fences. Straining posts shall not be spaced further apart than shown on the
Drawings. The length of posts above ground shall be such that the correct clearance between the
lowest wire and the ground can be obtained.
Posts shall be accurately set in holes and, where shown on the Drawings, provided with concrete
bases to the dimensions shown on the Drawings.

Corner, gate, end, and straining posts shall be braced by means of strays or anchors as shown on the
Drawings or as directed by the Engineer. Gateposts shall not be used as straining posts; but at each
gatepost, a straining post shall be placed as shown on the Drawings and stayed.
Standards shall be firmly anchored into the ground at the spacing shown on the Drawings or as
directed by the Engineer. The spacing of standards between any two straining posts shall be uniform
and not greater than shown on the Drawings. In rock or hard material, standards shall be either driven
or set in holes drilled into the rock. The size of drilled holes shall be such that a tight fit is obtained.
Care shall be exercised when driving standards to prevent buckling or damaging them.
All posts and standards shall be accurately aligned and set plumb. After posts and standards have
been firmly set in accordance with the foregoing requirements, the fence wire shall be attached thereto
at the spacing shown on the Drawings.
9807 Installing Wire

All fencing wire shall be wired to the sides of standards or posts to prevent the wires from being
displaced or becoming loose. The wire shall be carefully stretched and hung without sag, and with true
alignment, care being exercised not to stretch the wire so tightly that it will break, or that end corner,
straining or gate posts will be pulled up.
Each strand of fencing wire shall be securely fastened in the correct position to each standard with soft
galvanized binding wire. The binding wire for each horizontal fence wire shall pass through a hole or
notch in the standard to prevent slipping of the fence wire in a vertical direction, while the ends of the
wire shall be wound at least four times around the fencing wire to prevent it moving in a vertical
direction.
At end, corner, straining and gate posts the fencing wire shall be securely wrapped twice around the
posts and secured against slipping by tying the end tightly around the wire by means of at least six (6)
snug tight twists.
9808 Closing Openings under Fences

At open drains, streams, drainage channels or other hollows where it is not possible to erect the fence
so that it follows the general contour of the ground, the Contractor shall close the opening under the
fence by means of horizontal barbed wires at distances of 150 mm from each other, stretched between
additional posts or straining posts as shown on the Drawings or directed by the Engineer.
9809 Existing Fences

Where a new fence joins an existing fence, whether in line or at an angle, the new fence shall be
erected with a new straining post positioned at the terminal of the existing fence.
Existing fences that are required to be taken down or moved to a new location shall be dismantled.
Material not required for re-erection or declared unsuitable for re-use shall be neatly stacked at
approved locations in accordance with the Engineer's instructions. Fencing wire or netting shall be
stacked clear of the ground.
In the case of fences that require moving the Contractor shall re-use all material declared suitable for
this purpose by the Engineer, plus such new materials as may be required to re-erect the fence to the
standard specified for new fences. The Engineer shall not be responsible for any delays or costs
arising from breakage of reused wire during straining.

9810 Installing Gates

Gates shall be installed at the positions indicated by the Engineer. The gates shall be hung on gate
fittings in accordance with the requirements shown on the Drawings. Gates shall be so erected as to
swing in a horizontal plane at right angles to the gateposts, clear of the ground in all positions. At
pedestrian and security fences the double swing gates shall not leave a gap of more than 25 mm
between them when closed and other gates shall not be further than 25 mm from the gate post when
closed.

Fencing, either new or repositioned, shall be placed alongside the new road reserve in areas where
any existing fence will be removed or disturbed by the Works.
The completed fence shall be plumb, taut, true to line and ground contour, with all posts, standards,
and strays firmly set. The height of the lower fencing wire above the ground at posts and standard
shall not vary from that shown on the Drawings by more than 25 mm. Other fencing wires shall not
vary by more than 10 mm from their prescribed relative vertical positions.
Where temporary fences are erected they shall be firm and of sufficient height with a sufficient number
of wires to prevent the passage of livestock.
The Contractor shall, on completion of each section of fence, remove all cut-offs and other loose wire
or netting so as not to create a hazard to grazing animals or a nuisance to the owners of the land.

Item 98.01 Fencing ................................................................................................ kilometre (km)

The unit of measurement shall be the kilometre of fence line completed, measured along each fence
line.
The tendered rate shall include procuring, furnishing, placing and fixing all materials including posts
standards and barbed wire; and excavation and disposal of material.
Item 98.02 New gates (size and type indicated) .................................................... number (No)
The unit of measurement shall be the number of new gates erected.
The tendered rate shall include procuring and furnishing of all materials, including gates, gate posts,
hinges, bolts, concrete and straining wire; erection of the gates as specified and as shown on the
Drawings excluding any fencing wire erected on the gate; and excavation and disposal of material.
Item 98.03 Moving of existing fences and gates:

(a) Fences ......................................................................................................... kilometre (km)
(b) Moving of gates. ............................................................................................. .number (No)
The unit of measurement for moving existing fences shall be the kilometre of fence and the quantity
shall be taken as the length of fence which is permanently erected using material arising from fences
which have been dismantled elsewhere. The unit of measurement for moving of gates is the number of
gates moved.

The tendered rate shall include dismantling the old fence or gate, coiling and stacking of material not
suitable for reuse; moving of all material, including posts and wire; re-erection of the fence or gate in
the new position; the provision of binding, tying and straining wire; and new bolts, nuts and other
accessories required, but excluding new gate posts.

Division 9900: Footways and Masonry and Concrete Safety

Barriers
9901 Scope
The work shall consist of constructing footways and masonry and concrete safety barriers at locations,
lines, levels and dimensions as specified in the Drawings or as directed by the Engineer. The scope of
the work shall include provision of all drainage arrangements as shown in the Drawings or as directed.
9902 Footway
(a) Materials
The footways shall be constructed with pre-cast cement concrete blocks/tiles of Grade C-25 as per
Division 8400 of the Specifications. The minimum thickness of the cement concrete block/tile shall be
25 mm and minimum size shall be 300 mm x 300 mm.
(b) Construction Operations

Drainage pipes below the footway originating from the kerbs shall be first laid in the required slope and
connected to the drains/sumps/storm-water drain/drainage chutes as per provisions of the Drawings,
or as directed by the Engineer.
The base shall be prepared and finished to the required lines, levels and dimensions as indicated in
the Drawings with the following:-
 Minimum 150 mm thick, compacted granular sub-base material as per Division 5100 of the
Specifications.
 Minimum 25 mm thick cement concrete of Grade C 20/40.
Whenever there is provision for a covered drain, the concrete level shall be flush with the top of the
cover slab of the drain.
Precast cement concrete blocks/tiles shall be set on a layer of average 12 mm thick cement:sand
mortar (1:3) laid on a prepared base in such a way that there is not rocking. The gaps between the
blocks/tiles shall not be more than 12 mm and shall be filled with cement:sand mortar (1:3).
9903 Masonry Safety Barriers

Masonry Safety Barrier shall be constructed as shown on the Drawing with lean concrete conforming
to the requirements of Division 8400 and Class B Stone Masonry conforming to the requirement of
Clauses 3405 and 8903 of these Specifications.
9904 Precast Concrete Safety Barriers

Precast concrete safety barriers shall be supplied to the specifications of ASTM C 825 “Standard
Specification for Precast Concrete Barriers”. The barriers shall be constructed as shown on the
Drawings with concrete conforming to the requirements of Division 8400.
Unless otherwise instructed by the Engineer, any reinforcement shall be as supplied by the
manufacturer of the barriers and shall be sufficient to permit handling, delivery and placement of
precast sections without damage. The minimum concrete cover shall be 50 mm, except end sections
where the cover may be less.
Anchorage to prevent lateral movement of the barrier shall consist of dowels, keyway joints or
interlocking devices as shown on the Drawings, or instructed by the Engineer.
9905 Measurement for Payment

Item 99.01 Footway .......................................................................................... square metre (m²)

Footways shall be measured in square metres between inside of kerbs.
The tendered rate shall include excavation and disposal of surplus materials; preparation of
foundations, trimming and laying falls; procurement of materials including concrete slabs and bedding
material but excluding the granular sub-base material; and laying, bedding and jointing the blocks/tiles.
Item 99.02 Safety Barrier

(a) Masonry ...................................................................................................... linear metre (m)
(b) Precast Concrete (cross-sectional dimensions specified). ......................... .linear metre (m)
(c) In-situ concrete (cross-sectional dimensions specified) .............................. linear metre (m)
Masonry, precast concrete and in-situ concrete safety barriers shall be measured by the linear metre
of the length of barrier constructed. The gap between two adjacent units of masonry or concrete
barrier shall not be measured.
The tendered rate shall include excavation and disposal of surplus materials; preparation of
foundations, trimming and laying falls; masonry as item coverage in Pay Item 89.01; concrete as item
coverage in Pay Item 84.01. The rate shall also include the procurement, transport, placing and
anchoring of all precast concrete units.

Series 10000: Testing Materials and Workmanship
TABLE OF CONTENTS
DIVISION 10100: STANDARDS AND TESTING .......................................................................................... 742
10101 Scope ................................................................................................................................ 742
10102 Testing Methods ................................................................................................................ 742
10103 Costs of Testing ................................................................................................................. 742
(a) Process control .............................................................................................................................. 742
(b) Producing certificates .................................................................................................................... 742
10104 Taking and Submitting Samples ........................................................................................ 742
10105 Testing Aggregates ............................................................................................................. 744
(a) General .......................................................................................................................................... 744
(b) Determining acid insolubility ........................................................................................................ 744
(c) Free-water content ........................................................................................................................ 744
(d) Bulking the fine aggregates ........................................................................................................... 745
(e) Determining the effect of sand on the water demand of a concrete mix ....................................... 745
(i) Method:..................................................................................................................................................... 745
(f) Accelerated-test method for determining the potential alkali reactivity of aggregates ................. 745
(i) Test method ............................................................................................................................................... 745
(ii) Criteria ...................................................................................................................................................... 746
10106 Testing Concrete ............................................................................................................... 746
(a) Determining the compressive strength .......................................................................................... 746
(i) Plastic concrete ......................................................................................................................................... 747
(ii) Stiff concrete ............................................................................................................................................. 747
(iii) Consistency ............................................................................................................................................... 747
(b) Air content .................................................................................................................................... 747
(c) Drilling and testing the concrete cores .......................................................................................... 747
(d) Flexural strength test (modulus of rupture) ................................................................................... 747
(e) Curing concrete cubes to attain accelerated strength development (55°C/20 hours) .................... 747
(i) Scope ........................................................................................................................................................ 747
(ii) Apparatus .................................................................................................................................................. 747
(iii) Method ...................................................................................................................................................... 747
(iv) Calculating the compressive strength ....................................................................................................... 748
10107 Testing the Soils, Gravels and Crushed Stone Materials for Earthworks and Pavement
Layers ....................................................................................................................................... 748

(a) Field Density .................................................................................................................................748
(i) Nuclear device for compaction process control ........................................................................................ 748
(b) Relative Density ............................................................................................................................ 748
(c) Chemically stabilised material ......................................................................................................748
(d) Moisture content at saturation .......................................................................................................748
(e) The soundness of mudrock or shale aggregates ............................................................................749
(ii) Apparatus .................................................................................................................................................. 749
(iii) Preparation of aggregate ........................................................................................................................... 749
(iv) Test procedure (start of first cycle) ........................................................................................................... 749
(v) Evaluation ................................................................................................................................................. 749
(vi) Classification............................................................................................................................................. 750
10108 Determining the Bulk and Apparent Relative Density and Water Absorption ..................... 750
10109 Testing of Bitumen and Asphalt ......................................................................................... 750
(a) Tests described in the standard specifications for bitumen and bituminous emulsions .................750
(b) Determining the film thickness .....................................................................................................750
(c) Cantabro abrasion test ...................................................................................................................750
(i) Apparatus .................................................................................................................................................. 751
(ii) Test Procedure ........................................................................................................................................... 751
(iii) Calculations .............................................................................................................................................. 751
(d) Determination of in-situ water permeability of bituminous road surfacing or road base layers by
using the falling head (MARVIL) apparatus .................................................................................752
10110 Tests Relating To Chemical Stabilisation ........................................................................... 752
(a) Test for cementitious binder content ............................................................................................. 752
(b) Canvas-patch test for the spreading rate of cementitious binder ...................................................752
(c) Test for mix uniformity in chemically stabilised layers ................................................................ 752
10111 Tests on Pavements ................................................................................................................. 753
(a) Determining the texture depth .......................................................................................................753
(b) Straightedge test for surface irregularities on surfaces with a coarse surface texture ...................753
(c) Using the rolling straight-edge for measuring surface irregularities .............................................753
10112 Structural Tests ................................................................................................................... 753
(a) Tests on elastomeric bearings ........................................................................................................753
(i) General ...................................................................................................................................................... 753
(ii) Compression and shear-stiffness tests ....................................................................................................... 753
(b) Pre-stressed concrete: Testing pre-stressing steel, Anchorage assemblies, couplings and grout ...753
(i) General ...................................................................................................................................................... 753

(ii) Anchorages and couplers .......................................................................................................................... 754
(iii) Pre-stressing steel ..................................................................................................................................... 754
(iv) Grout ......................................................................................................................................................... 754
(c) Load test on foundation piles ........................................................................................................ 755
10113 Tests on Silicone Sealants ................................................................................................. 756
(a) Bond to cement mortar .................................................................................................................. 756
(b) Non-adhesive period ..................................................................................................................... 756
(c) Deformability and adhesion .......................................................................................................... 756
10114 Tests on Geotextiles and Geotextile-Soil Compatibility Tests ............................................ 756
(a) Puncture resistance tests on geotextiles ........................................................................................ 756
(i) Apparatus .................................................................................................................................................. 756
(ii) Clamping device ....................................................................................................................................... 756
(iii) mounting device ....................................................................................................................................... 756
(iv) Cone assembly .......................................................................................................................................... 757
(v) Measuring device ...................................................................................................................................... 757
(vi) Marking and cutting stencil ...................................................................................................................... 757
(vii) Felt pen and punch ......................................................................................................................... 757
(viii) Number of specimens..................................................................................................................... 757
(ix) Preparation of specimens .......................................................................................................................... 757
(x) Procedure .................................................................................................................................................. 758
(xi) Testing ...................................................................................................................................................... 758
(xii) Calculation and reporting ............................................................................................................... 758
(xiii) Reporting ....................................................................................................................................... 758
(xiv) Information sheet ........................................................................................................................... 758
(b) Permeability reduction (flow test) ................................................................................................. 758
(i) Water supply ............................................................................................................................................. 758
(ii) Cutting device ........................................................................................................................................... 758
(iii) Miscellaneous equipment ......................................................................................................................... 758
(iv) Number of specimens ............................................................................................................................... 759
(v) Geotextile specimens ................................................................................................................................ 759
(vi) Soil samples .............................................................................................................................................. 759
(vii) Procedure ....................................................................................................................................... 759
(viii) Calculations ................................................................................................................................... 760
(ix) Information sheet ...................................................................................................................................... 760
10115 Classifying the Tests .......................................................................................................... 760

(a) Ordinary Tests ............................................................................................................................... 760
(b) Special Tests ..................................................................................................................................760
(c) Payment .........................................................................................................................................761
10116 Testing of Construction Water ............................................................................................ 761
(a) Compressive strength test ..............................................................................................................761
(b) Inorganic impurities criteria ..........................................................................................................761
10117 Measurement and Payment ............................................................................................... 761
DIVISION 10200: QUALITY CONTROL (SCHEME 1) .................................................................................. 771
10201 Scope ................................................................................................................................ 771
10202 Judgment Plans: General .................................................................................................. 771
10203 Definitions ........................................................................................................................... 772
(a) Lot .................................................................................................................................................772
(b) Random sample ............................................................................................................................. 772
(c) Sample mean ( xn ) ........................................................................................................................ 772
(d) Sample standard deviation ( S n ) ...................................................................................................772
(e) Specification limit (Ls) ..................................................................................................................772
(f) Acceptance limit (La) ....................................................................................................................772
(g) Conditional acceptance .................................................................................................................773
(h) Rejection limit (Lr)........................................................................................................................ 773
(i) Payment reduction factor (fr) ........................................................................................................773
(j) Outliers ..........................................................................................................................................773
(k) Factors ka, kad, kr, and krd ...........................................................................................................773
(i) Acceptance limits (La and L'a) ................................................................................................................. 773
(ii) Rejection limits (Lr and L'r): .................................................................................................................... 773
(iii) Ø (%)......................................................................................................................................................... 773
(l) First submission ............................................................................................................................ 773
(m) Resubmission ................................................................................................................................ 773
(n) Rehabilitation and repair work ......................................................................................................774
10204 General Requirements ...................................................................................................... 774
(a) Determining lot size ...................................................................................................................... 774
(i) Road construction layers ........................................................................................................................... 774
(ii) Concrete .................................................................................................................................................... 774
(iii) Other ......................................................................................................................................................... 774

(b) Random sampling ......................................................................................................................... 774
(c) Sample sizes .................................................................................................................................. 774
(d) Outliers.......................................................................................................................................... 774
(i) Method 1................................................................................................................................................... 775
(ii) Method 2 ................................................................................................................................................... 776
(e) Resubmission ................................................................................................................................ 777
(i) The Fisher F-test ....................................................................................................................................... 777
(ii) The t-test ................................................................................................................................................... 778
10205 Judgement Plan A (Surface Levels and Layer Thicknesses) ............................................ 780
(a) Taking the levels ........................................................................................................................... 780
(b) Calculating the deviations ............................................................................................................. 780
(c) Identifying outliers ........................................................................................................................ 780
(d) Assessing the results ..................................................................................................................... 780
(i) Surface levels ............................................................................................................................................ 780
(ii) Layer thickness ......................................................................................................................................... 780
10206 Judgement Plan B .............................................................................................................. 781
(a) Taking samples and testing the properties ..................................................................................... 781
(b) Identifying outliers ........................................................................................................................ 781
(c) Calculating standard deviation and the mean of sample values .................................................... 781
(d) Determining the judgement limits ................................................................................................. 782
(e) First submission ............................................................................................................................ 782
(f) Resubmission ................................................................................................................................ 782
(g) Values of constants ........................................................................................................................ 783
(h) Requirements for non-structural concrete ..................................................................................... 784
10207 Controlling More Than One Property ................................................................................. 785
10208 Conditional Acceptance..................................................................................................... 785
(a) General .......................................................................................................................................... 785
(b) Properties to which conditional acceptance applies ...................................................................... 785
(c) Criteria for conditional acceptance ............................................................................................... 786
(d) Applying the payment-reduction factor ........................................................................................ 787
10209 Process Control by the Contractor .................................................................................... 787
10210 Routine Tests and Inspection by the Engineer.................................................................. 788
10211 Determining Rejection Limits in accordance with Statistical Criteria ................................ 788
(a) For a single-limit specification ..................................................................................................... 788
(b) For a double-limit specification .................................................................................................... 789

DIVISION 10300: QUALITY CONTROL (SCHEME 2) .................................................................................. 790
10301 Scope ................................................................................................................................. 790
10302 Judgement Plans: General ................................................................................................. 790
10303 Definitions ........................................................................................................................... 790
(a) Lot .................................................................................................................................................790
(b) Random sample ............................................................................................................................. 790
(c) Sample mean ( xn ) ........................................................................................................................ 790
(d) Specification limit (Ls) ..................................................................................................................791
(e) Acceptance limit for sample mean (La) ......................................................................................... 791
(f) Acceptance limits for individual test values Le .............................................................................791
(g) Conditional acceptance .................................................................................................................791
(h) Outliers ..........................................................................................................................................791
(i) First submission ............................................................................................................................ 791
(j) Resubmission ................................................................................................................................ 791
(k) Payment reduction factor (fr) .........................................................................................................791
(l) Rehabilitation and repair work ......................................................................................................791
10304 General Requirements ....................................................................................................... 792
(a) Determining the lot size ................................................................................................................792
(i) Road construction layers ........................................................................................................................... 792
(ii) Concrete .................................................................................................................................................... 792
(iii) Other ......................................................................................................................................................... 792
(b) Random sampling .......................................................................................................................... 792
(c) Sample sizes ..................................................................................................................................792
(d) Outliers ..........................................................................................................................................792
(i) Method 1 ................................................................................................................................................... 792
(ii) Method 2 ................................................................................................................................................... 793
(e) Resubmission ................................................................................................................................ 794
10305 Procedures ........................................................................................................................ 794
(a) Surface levels of fills and pavement layers ...................................................................................794
(b) Layer thicknesses of pavement layers ........................................................................................... 795
(c) Relative compaction of pavement layers ....................................................................................... 795
(d) Cementitious binder content of stabilised layers and uniformity of mix .......................................795
(e) Binder content of asphalt ...............................................................................................................796
(f) Concrete: 28-day cube compressive strength ................................................................................798

10306 Controlling more than one Property ................................................................................... 799
10307 Conditional Acceptance...................................................................................................... 799
(a) General .......................................................................................................................................... 799
(b) Properties to which conditional acceptance applies ...................................................................... 799
(c) Criteria for conditional acceptance ............................................................................................... 800
(i) Case 1 ....................................................................................................................................................... 800
(ii) Case 2 ....................................................................................................................................................... 800
(d) Determining the payment reduction factor (fr) ............................................................................. 801
(ix) Case 1 ....................................................................................................................................................... 801
(x) Case 2 ....................................................................................................................................................... 801
(e) Applying the payment reduction factor ......................................................................................... 802
10308 Process Control by the Contractor .................................................................................... 802
10309 Quality of Materials and Workmanship .............................................................................. 803

LIST OF TABLES
Table 10104/1: Schedule Showing Quantities and Times for Submitting the Materials for Approval and
Mix Designs ................................................................................................................................. 744
Table 10108/1: Test Methods for Apparent and Bulk Density and Water Absorption .......................... 750
Table 10116/1: Criteria for Inorganic Impurities in Water Used To Manufacture Concrete ................. 761
Table 10204/1: Critical Values (Except Road Base and Asphalt Mixes) ............................................. 775
2
Table 10204/2: Values of x 0.99 Distribution ....................................................................................... 776
Table 10204/3: Outlier Test for Road base: Critical Values ................................................................. 776
Table 10204/4: Outlier Test for Asphalt: Critical Values C ................................................................... 777
Table 10204/5: Values of F Distribution (Σ = 0.05) .............................................................................. 779
Table 10204/6: Values for T-Distribution (Σ = 0.05) ............................................................................. 780
Table 10206/1: Characteristic Properties: Judgement Plan B ............................................................. 781
Table 10206/2: Minimum Sample Sizes For Concrete (Structural) ..................................................... 781
Table 10206/3: Values of Constants N, Ls, L's and Ø ......................................................................... 783
Table 10206/4: Values of Ka (Single Limits) ......................................................................................... 784
Table 10206/5: Values of Kad (Double Limits)..................................................................................... 784
Table 10208/1: Properties for which conditional acceptance may be applied ..................................... 785
Table 10208/2: Rejection Limits (Lr and L'r) For Sample Mean ( ) ................................................. 787
x n
Table 10211/1: Values of Kr (Single-Limit Specification) ..................................................................... 789
Table 10211/2: VALUES OF krd (DOUBLE-LIMIT SPECIFICATION) ................................................. 789
Table 10304/1: Critical Values ............................................................................................................. 793
Table 10304/2: Outlier Test for Road base: Critical Values C .............................................................. 794
Table 10304/3: Outlier Test for Asphalt: Critical Values C ................................................................... 794
Table 10305/1: Acceptance Limits in Respect of Compaction............................................................. 797
Table 10305/2: Acceptance Limits for Bituminous Binder Content ...................................................... 798
Table 10305/3: Acceptance Factors for Concrete Strength ................................................................. 798
Table 10305/4: Minimum Sample Sizes for Strength Concrete (Structural) ........................................ 799
Table 10307/1: Properties to which Conditional Acceptance may apply ............................................. 799
Table 10307/2: Rejection Limits (Lr and L'r) for the Sample Mean ( x n ) ............................................ 801
Table 10307/3: Payment Reduction Factors for Conditionally Accepted Bituminous Binder Application
Rates ........................................................................................................................................... 802

LIST OF FIGURES
Figure 10100/1: Weathering Apparatus............................................................................................... 762
Figure 10100/2: Visual Classification for Mudrocks and Shale Aggregate Soundness Test ............... 763
Figure 10100/3: Marvil Apparatus ....................................................................................................... 764
Figure 10100/4: Grease Ring for Marvil Test ...................................................................................... 764
Figure 10100/5: Placing of Prestik sealant for Marvil Apparatus ........................................................ 765
Figure 10100/6: Placing Of Plaster Of Paris for Marvil Apparatus (if required) .................................. 765
Figure 10100/7: Flow Cone for Measuring the Fluidity of Grout ......................................................... 766
Figure 10100/8: Metal or Glass Container for measuring the Bleeding of Grout ................................ 767
Figure 10100/9: Cone Assembly and Measuring Device for Puncture Resistance Test on Geotextiles
.................................................................................................................................................... 768
Figure 10100/10: Permeameter for Permeability Production Tests (Flow Tests) ................................ 769
Figure 10100/11: Permeability Reduction Criteria ............................................................................... 770

Division 10100: Standards and Testing
10101 Scope
During the progress of the work tests shall be conducted on materials and workmanship to ensure
compliance with the requirements of the specifications
Certain sampling and testing procedures not covered in the other sections of the specifications by
reference to the standard methods mentioned in Clause 10102 are given in this section
10102 Testing Methods

All tests shall be conducted in accordance with the standard methods specified in the following:
 The specifications of the American Society for Testing and Materials (ASTM);
 The specifications of the American Association of State Highway and Transportation Officials
(AASHTO);
 British Standards Institute Specifications (BS);
 The South African National Standards (SANS) 3001 Series published by the South African
Bureau of Standards (SABS).
 Other SABS methods as specified.
In addition to the above standard methods of testing, standard specifications or test methods of other
bodies may also be referred to in these Specifications, or test methods may be described where no
acceptable standard methods exist.
All standards for test method shall be supplied in line with the requirements of sub-clause 1205 (c)
Note: In all cases the latest amendment or revision prevailing at the closing date of the tender is
implied when reference is made to one of the above standards in the specification.
10103 Costs of Testing
(a) Process control

The cost of testing undertaken by the Contractor in terms of his obligations under the Conditions of
Contract for purposes of process control; including the taking of samples; reinstating where samples
have been taken; and all testing equipment, labour, materials etc shall be included in the rates
tendered for the various items of work supplied; and will not be paid for separately.
(b) Producing certificates

The Contractor shall supply the Engineer with certificates of compliance to the specification for all
manufactured products and materials for use in the Works. Such products shall include, but not be
limited to; cement; bitumen; steel reinforcement; bridge bearings; corrugated metal pipe culverts;
gabion baskets etc. Should the Contractor wish to change the source of such products, new
certificates of compliance shall be supplied.
10104 Taking and Submitting Samples

The method of taking samples shall be as specified in the appropriate sampling and testing methods.
The sampling methods described in TMH 5 of the South African Department of Transport; SABS
method 827; ASTM and AASHTO shall apply where relevant. If no sampling method is specified, the
sampling methods described in TMH5 and in SABS method 827 shall take precedence. Copies of the
relevant sampling procedures should be obtained by the Contractor as specified in sub-clause

1205(c).
In the case of rehabilitation work the definitions given in the Particular Specifications for lot, lot size,
random sample and sample size shall apply.
Where the Contractor is required in these specifications to submit samples of materials or mixtures to
the Engineer for approval prior to their being used in the Works, the use of these materials or mixtures
without the Engineer's written approval shall constitute default on the part of the Contractor, who shall
be liable for the consequence of such default. All samples shall be submitted in sufficient time for
proper testing.
The Engineer's approval of any materials or mixtures shall in no way relieve the Contractor of his
obligation to provide materials, mixtures and workmanship, which comply with the Specifications.
All samples for testing shall be taken in a random pattern or as prescribed by the Engineer. Where
specified or required by the Engineer, stratified random sampling methods shall be followed. For the
testing of layer work stratified random sampling methods shall be used for obtaining all the sample
portions and for determining the locations for in-situ tests.
The Engineer shall have full access to the works for the purpose of taking samples. The Contractor
shall render any assistance necessary for taking the samples and shall be responsible for the
reinstatement of pavement layers or other structures at the positions where the samples have been
taken. Full compensation for rendering assistance with sampling and for reinstatement where samples
have been taken shall be included in the rates tendered for the various items of work tested, and no
additional payment will be made in this respect.
Table 10104/1 provides guidelines in respect of submitting the materials in regard to the time and
quantity of material required for testing, approval and the mix design. As the time stated in this table
does not make any allowance for possible rejection and the resubmission of alternative materials, the
Contractor shall submit any materials of uncertain quality at an early stage or together with alternative
materials in order to minimise any delays in final approval.
The Contractor shall note that any samples submitted direct to the Engineer's laboratory for approval
shall be properly marked and shall be accompanied by a covering letter with all the required
information and countersigned by the Engineer.

Table 10104/1: Schedule Showing Quantities and Times for Submitting the Materials for
Approval and Mix Designs
Submission for quality approval Submission for quality approval and

only mix design
Material Minimum time to Minimum time to
Proposed use Minimum Minimum
submitted be allowed for be allowed for
quantity to be quantity to be
testing and testing, approval
submitted submitted
approval and mix design
150 kg of each
Coarse 8 weeks for
50 kg of each size size of stone for
Aggregate for 2 weeks structures and
of stone each class of
concrete concrete roads
concrete
Bituminous 50 kg of each size 50 kg of each size
Crushed 2 weeks 2 weeks
seals of stone of stone
stone
50 kg of each size 100 kg of each
Asphalt mixes 2 weeks 8 weeks
of stone size of stone
Crushed-stone
8 weeks
base or sub- 3 weeks 50 kg 200 kg
(stabilisation)
base
150 kg of each
Fine Aggregate 50 kg of each size type proposed for
2weeks 10 weeks
for concrete of aggregate use for each class
of concrete
Crusher dust 150 kg of each
15 kg of each size
and/or sand Asphalt mixes 2weeks 8 weeks type proposed for
of aggregate
use
15 kg of each 50 kg of each
Slurry or sand
2 weeks type proposed for 6 weeks type proposed for
seal
use use
Sub-base and/or 200 kg of each 8 weeks
Gravel 4weeks 200 kg
base sample (stabilisation)
Other
materials eg
paint, As specified As prescribed by the Engineer
cement,
additives, etc
10105 Testing Aggregates
(a) General
The Contractor as part of his process control shall regularly test aggregates, as they are being
manufactured; or brought onto the site and used; or taken to stockpile.
(b) Determining acid insolubility

A sample of fine aggregate with an approximate mass of 1 kg shall be dried and weighed. The sample
shall then be treated with an adequate amount of a 6-N solution of hydrochloric acid to react with all
the acid-soluble particles in the sample. When the reaction is complete, the residue shall be removed
from the solution by filtration (Whatman No 4 filter paper), washed with water, screened through a
0.075 mm sieve, dried and weighed. The mass of insoluble residue retained on the 0.075 mm sieve,
expressed as a percentage of the total sample, shall be reported as the acid-insoluble content.
(c) Free-water content

The free-water content of aggregate shall be determined in accordance with SANS 5855. Rapid-
testing methods approved by the Engineer may also be applied.
Suitable adaptations of this method may be used for determining the free-water content of coarse
aggregate.
(d) Bulking the fine aggregates

The bulking of fine aggregates shall be determined in accordance with SANS 5856.
(e) Determining the effect of sand on the water demand of a concrete mix
Water demand is defined as the quantity of water per cubic metre of concrete required to give a slump
of 75 mm in a concrete with an optimum quantity of stone with a nominal size of 19 mm.
The following materials are required:
 Ordinary Portland cement;

 Crushed stone with a nominal size of 19 mm;
 Sand or a sand mix to be tested.
(i) Method:
1. Determine the relative density (Rsa) in accordance with SANS 5844 and the fineness modules
(FM) of the sand or sand mix.
2. Determine the compacted bulk density (CBD) of the 19 mm Aggregate in accordance with
SANS 5845. Also determine the relative density of the stone (Rst)
3
3. Determine the required quantity of stone (S) per cubic metre of mix (in kg/m ) in accordance
with formula:
S = CBD (0.975 - 0.1 FM).
3 3
4. Estimate the water demand (W) of the mix (in l/ m ). (220 l/m may be used as a starting
point.)
3
5. Determine the required cement content (C) for the mix (in kg/m ) by using the water content
(W) as obtained from (4) and a water-cement ratio of 0.59.
3
6. Determine the desired sand content (SC) of the mix (in kg/m ) in accordance with the formula:
SC = 1 - (C/3140 + W/1000 + S/Rst)
7. Decide on the mix size, which will apply to the available equipment and calculate the mix
quantities in relation to the calculated quantities per cubic metre. Do not produce a mix of less
than 10 l.
8. Prepare the mix and determine the slump in accordance with SANS 5862-1. Repeat the test
with adjusted quantities of cement, water and sand until a slump of 75 mm is achieved. (As a
3
rule, a change of 10 l/m in the water content either halves or doubles the slump.)
9. The water content giving a slump of 75 mm will then be the water demand for the mix.
10. In order to facilitate the repeatability of results the following parameters should be kept
constant:
a. Material temperature
b. Mixing time
c. Source of cement
d. Source of stone.
(f) Accelerated-test method for determining the potential alkali reactivity of aggregates
(i) Test method

Three mortar prisms shall be prepared in accordance with the requirements of ASTM C 227-90. The
prisms are removed from the mould after 24 hours and immersed in water in a closed container,
placed in an oven and kept at a constant temperature of 80ºC. After 24 hours in the oven, the prisms

are taken to a room with a temperature of 23ºC where their lengths are measured with a vertical
comparator (an indicator type of deformation metre) to an accuracy of 2 μm before any significant
cooling takes place.
This reading will be taken as the nil reading.
After the initial reading has been taken, the prisms are immersed in a 1-N sodium hydroxide solution
kept at 80ºC in a tightly sealed plastic container, which is large enough for the prisms to be completely
immersed (NB - glass and metal containers are unsuitable as they are susceptible to attack by the
caustic solution). The prisms are measured every working day for a period of 14 days at a room
temperature of 23ºC and their linear expansion is calculated. The average expansion of the three
prisms for each day is then calculated. Where none of the values deviate by more than 15% from the
average, the repeatability is regarded as being satisfactory. The average expansion after 10 or 12
days is taken to be the reference value for determining the potential alkali reactivity.
(ii) Criteria
The proposed criteria for the accelerated mortar-prism testing method shall be as follows:
 Percentage of linear expansion after 10 days.

o < 0.08: the alkali reactivity of the aggregate is not harmful
o ≥ 0.08 but < 0.20: the alkali reactivity of the aggregate is harmful and the aggregate is
expanding slowly
o ≥ 0.20: the alkali reactivity of the aggregate is harmful and the aggregate is expanding
rapidly
 Percentage of linear expansion after 12 days:
o < 0.10: the alkali reactivity of the aggregate is not harmful
o ≥ 0.10 but < 0.25: the alkali reactivity of the aggregate is harmful and the aggregate is
expanding slowly
o ≥ 0.25: the alkali reactivity of the aggregate is harmful and the aggregate is expanding
rapidly.
 Interpretation
3
o For aggregates falling in the slowly expanding group, the alkalinity per m of concrete
3
shall not exceed 2.80 kg of a Na2O equivalent per m .
3
o For aggregates falling in the rapidly expanding group, the alkalinity per m of concrete
3
shall not exceed a value of 2.10 kg of a Na2O equivalent per m , depending on the
reactivity.
The dilution and palliative effect of extenders in the cementitious binders such as slagment (where
permitted in structural concrete) and fly ash shall be taken into account in the interpretation of the
results.
10106 Testing Concrete
(a) Determining the compressive strength

The procedure for sampling and manufacturing, storing, curing and testing test cubes shall be in
accordance with SANS 30001-CO11, except that the machines referred to shall also comply with all
the requirements of BS 1610 and BS 1881.
Deviations from the procedure shall apply where the Engineer instructs that the compaction of
concrete specimens in the moulds by means of a vibrating table shall be obligatory.
The vibratory method of compaction shall be as follows:
(i) Plastic concrete

Fill the mould halfway; vibrate it; and spade it on all four sides with a suitable trowel to remove air
bubbles. Stop the vibration as soon as a wet sheen appears on the surface. Fill the mould and repeat
the procedure, but stop when again a wet sheen appears on the surface.
(ii) Stiff concrete

The same procedure is followed, except that the mould is filled in three to four steps, instead of in two.
The vibration is stopped for each layer when a wet sheen appears.
(iii) Consistency
The test method described in SANS 3001-CO2 shall apply in regard to the slump test, and the method
described in SANS 3001-CO4 in regard to the VEBE test.
(b) Air content

The air content of the freshly mixed concrete shall be tested by the method given in SANS 3001-
CO22. Air content tests shall be conducted on the same samples of concrete from which cubes were
made for the 28-day compressive-strength tests.
(c) Drilling and testing the concrete cores

Where sections of concrete that have failed to comply with the specifications are required to be further
investigated by extracting and testing concrete cores, 100 mm or 150 mm cores shall be drilled and
tested. The sampling and testing procedure to be followed shall be in accordance with SANS 3001-
CO6.
(d) Flexural strength test (modulus of rupture)

The procedure for sampling, making tests beams, curing, storing and testing, and the moulds used,
shall be in accordance with SANS 3001-CO12.
(e) Curing concrete cubes to attain accelerated strength development (55°C/20 hours)
(i) Scope
A method is described for curing concrete cubes at 55ºC for 20 hours with a view to predicting the 28-
day compressive strength for purposes of quality control. The accelerated tests are additional tests
and do not replace the 28-day tests.
(ii) Apparatus
The following equipment is required:
 Apparatus for preparing the concrete cubes in accordance with SANS 3001-CO11
 Plastic sheets of 180 mm x 180 mm
 Hessian sheets for covering the samples
 A suitable water bath with a circulation system of adequate capacity and a thermostat to
maintain the temperature constantly at 55ºC ± 1ºC.
(iii) Method
Prepare the required number of concrete cubes in accordance with SANS 3001-CO11 and completely
cover the exposed surface within the cube mould with small plastic sheets and then with wet hessian.
Keep covered for 3 hours ± 15 minutes.
Place the concrete cubes in their moulds in the hot-water bath at a rate which will not cause the water
temperature to drop below 54ºC. Record the exact time when each cube is placed into the water and
leave in the water at a temperature of 55ºC ± 1ºC for 20 hours ± 15 minutes.

Remove the moulds containing the cubes from the water and then carefully remove the cubes from
their moulds. Cool the cubes for 2 hours ± 15 minutes in water at 20ºC ± 5ºC.
Test the compressive strength of the cubes in accordance with SANS 3001-CO11.
(iv) Calculating the compressive strength

The cube compressive strength is calculated in accordance with SANS 3001-CO11. In order to predict
28-day compressive strength of concrete mixes, the ratio between the 28-day compressive strength
and the strength of rapidly-hardened cubes shall be determined for each type of concrete mix by
correlation techniques.
For purposes of the initial work, research has shown that the strength of the cubes treated and tested
as described above will be approximately 0.58 times the 28-day compressive strength for concrete
cubes prepared from Ordinary Portland cement (for strengths between 30 and 65 MPa). For rapid-
hardening cement, the corresponding factor is 0.59; and for PBFC it is 0.66.
10107 Testing the Soils, Gravels and Crushed Stone Materials for
Earthworks and Pavement Layers
Specimens of soils, gravels and crushed-stone materials in earthworks and pavement layers shall be
taken in accordance with the methods described in TMH5 (unless SABS 827 is specified), and any
tests thereon shall be conducted in accordance with the methods described in the prevailing test
method of the SANS 3001 series, all subject to the additional provisions stated herein.
(a) Field Density

All field-density determinations shall be done in accordance with SANS 3001-GR35 (sand replacement
method).
Unless otherwise directed by the Engineer, density testing for layerworks shall be carried out within 24
hours of compaction having been completed.
(i) Nuclear device for compaction process control

The nuclear device for compaction process control shall only be used if:
 Approved by the Engineer:

 Operated by a suitably trained technician;
 In compliance with all the statutory regulations governing the use of this equipment;
 Certified to be suitably calibrated:
 Calibrated to the SANS 3001-GR35 method.
(b) Relative Density

The dry bulk relative density and the apparent relative density of crushed-stone material shall be
determined as specified in Clause 10108.
(c) Chemically stabilised material

In the case of chemically stabilised material, determining the optimum moisture content and the
maximum dry density shall be completed within the period given in Table 4503/1, and field density
shall be determined within 24 hours of compaction having been completed.
(d) Moisture content at saturation

The moisture content at the specified saturation degree (Sr) shall be determined as follows:

(The apparent density (Gs) of the material shall also be determined for this purpose).
W v = Sr (Xw/ Xd - 1000/ Gs), where:
Wv = moisture content of the specified degree of saturation (%)

3
Xw = density of water (kg/m )
3
Xd = dry field density of the material (kg/m )
3
Gs = apparent density of the material (kg/m )
Sr = specified degree of saturation (%).
(e) The soundness of mudrock or shale aggregates

The soundness of mudrock or shale aggregates shall be determined by weathering the aggregate in
water by means of the following method (Venter test):
(ii) Apparatus
 37.5 mm and 26.5 mm, 300 mm diameter sieves, complying with ISO 3310.
 Stainless steel weathering basins, 150 mm (L) x 100 mm (W) x 50 mm (H) with perforated
base (see figure 10104/1 (a))
 Stainless steel reaction troughs, 500 mm (L) x 160 mm (W) to hold three (3) weathering
basins (see figure 10104/1(b)).
 Stainless steel drip tray, 500 mm (L) x 450 mm (W) x 25 mm (H), to hold nine (9) weathering
basins for oven drying (see figure 10104/1(c)).
 Force draught oven, capable of maintaining a temperature between 105ºC and 110ºC
 Tank with distilled water supply.
(iii) Preparation of aggregate

For each laboratory sample, obtain six (6) representative aggregate particles passing the 37.5 mm
sieve and retained on the 26.5 mm sieve, without any visible cracks or flaws.
Place the particles in the weathering basin so that they are not touching each other.
(iv) Test procedure (start of first cycle)

Place the weathering basins containing the particles in the oven and dry overnight for 15 hours ± 30
minutes at a temperature between 105ºC and 110ºC.
Remove from the oven and allow to cool to room temperature for at least 30 minutes.
Place the weathering basins with aggregate particles in the reaction trough and add clean water until
the particles are covered by at least 15 mm of water.
Keep the aggregate particles immersed in the water at room temperature for 8 hours ± 30 minutes.
Lift the weathering basins containing the aggregate particles out of the water and, by tilting it through
90º, allow the weathering basins to rest on the inner shoulders of the trough for drip drying. This
completes the first cycle.
Visually inspect each particle and record the condition of each particle noting cracks, flaws, extent of
fissures etc. before starting the following cycle.
Repeat until five (5) cycles are completed and finally inspect each aggregate particle.
(v) Evaluation
The disintegration pattern of the aggregate fragments shall be visually classified in accordance with
the five classes illustrated in figure 10100/2.
The terms to be used to describe the shape of the fragments are as follows:

 Plates - plates of fairly uniform thickness.

 Flakes - fragments of non-uniform thickness, concave, convex, or wedge-shaped.
 Chunks - roughly equi-dimensional fragments (> 3 mm).
 Grains - fragments from about sand size to 3 mm diameter.
 Silt, mud or clay
(vi) Classification
The five classes for rating the aggregate are as follows:
 Class I: Nil to minimal disintegration with only minor closed cracks and difficult separation
along these fractures planes
 Class II: Disintegration into hard fragments with some open cracks.
 Class III: Moderate disintegration with a high percentage of open cracks into less hard
fragments.
 Class IV: Extensive disintegration into soft fragments with total separation along fracture
planes.
 Class V: Slaking into very soft fragments, silt, mud or clay
10108 Determining the Bulk and Apparent Relative Density and Water
Absorption
The apparent and bulk densities; and water absorption shall be tested as shown in Table 10108/1.
Table 10108/1: Test Methods for Apparent and Bulk Density and Water Absorption
Test Aggregate type SANS 3001

Apparent & Bulk Density and Water > 5 mm AG20
Absorption < 5 mm AG21
Apparent Density Crushed stone base AG22
10109 Testing of Bitumen and Asphalt
(a) Tests described in the standard specifications for bitumen and bituminous emulsions
The Engineer shall be entitled to order the Contractor to have materials tested by an approved
laboratory for compliance with all or any of the requirements specified, and the results of such tests
shall be submitted directly to the Engineer by the testing laboratory with copies, if requested, to the
Contractor.
The cost of such tests shall be borne as specified in Clause 10103.
(b) Determining the film thickness

The film thickness of the binder in asphalt mixes shall be determined as described in the publication
TRH 8 published by the South African Department of Transport and now under the auspices of the
South Africa National Road Agency Ltd (SANRAL).
(c) Cantabro abrasion test

Where required by the Particular Specifications, the resistance of porous asphalt briquettes to
abrasion loss shall be determined by means of the Cantabro test.
The details of the test are as follows.

(i) Apparatus
The apparatus shall be a Los Angeles Testing Machine as described in ASTM Method C131.
The machine shall consist of a hollow steel cylinder, closed at both ends, having an inside diameter of
710 mm ± 5 mm and an inside length of 510 mm ± 5 mm.
The cylinder shall be mounted with stub shafts attached to the end of the cylinder, but not entering it,
and shall be mounted in such a manner that it may be rotated with the axis in a horizontal position with
a tolerance in slope of 1 in 100.
An opening in the cylinder shall be provided for introduction of the test sample.
The opening shall be provided with a suitable, dust-tight cover secured in place by bolts.
The cover shall be designed to maintain the cylindrical contour of the interior surface unless the shelf
is so located that the charge and/or test sample will not fall on the cover, or come in contact with it
during the test.
A removable steel shelf extending the full length of the cylinder and projecting 90 mm ± 2 mm inward
shall be mounted on the interior cylindrical surface of the cylinder in such a way that a plane centred
between the large faces coincides with an axial plane.
The shelf shall be 25 mm ± 1 mm thick and mounted by bolts or other suitable means so that it is firm
and rigid.
The position of the shelf shall be such that the distance from the shelf to the opening, measured along
the outside circumference of the cylinder in the direction of rotation, shall not be less than 1 270 mm.
The machine shall be driven and counterbalanced to maintain uniform peripheral speed of 30 - 33 rpm
for 300 revolutions.
If an angle is used as the shelf, the direction of rotation shall be such that the charge is caught on the
outside surface of the angle.
(ii) Test Procedure

Marshall Specimens shall be prepared as described in SANS 3001-AS1, but for this test each Marshall
specimen shall be compacted with 50 blows only on each side.
For each binder content, three specimens shall be made for the abrasion test.
The compaction temperature depends on the type of binder to be used. For 60/70 penetration-grade
bitumen it shall be 115ºC to 120ºC and for bitumen-rubber (wet method) it shall be 135ºC to 140ºC
measured in the mould just prior to compaction.
The thickness of the test specimen shall be 63.5 mm ± 1.25 mm.
The mass of the specimen in air (P1) to the nearest 0.1 g and the average thickness to the nearest
0.1 mm shall be determined.
The test specimen shall be placed in the Los Angeles apparatus without the abrasive charge of steel
balls and the cover shall be fitted.
The machine shall be switched on and allowed to operate for 300 revolutions at a speed between 30 -
33 rpm.
After the required number of revolutions, the machine shall be stopped and the specimen removed
and the mass determined (P2) to the nearest 0.1 g.
The test shall be carried out for each binder content in triplicate.
(iii) Calculations
The percentage abrasion loss for each specimen shall be calculated as follows:

P = 100(P1 - P2)/P1 where:

P1 = mass of specimen before testing.
P2 = mass of specimen after testing.
The mean of the three specimens shall be determined at the various binder contents.
Notes:
The determination of the optimum binder content is based on the following considerations:
1/ a minimum binder content limit to ensure resistance against aggregate loss due to traffic and to enhance
durability
2/ a maximum binder content limit to avoid binder run-off and to ensure good drainage in the mix as a layer on the
road.
The minimum binder content to ensure adequate coating thickness shall not be less than 4%.
The density of the specimen can also be determined by calculating the volume of the specimen.
The voids in the specimen can also be calculated if the maximum theoretical voidless density (Rice) is
determined:
% Voids in specimen = 100 (Rice density - specimen density)/Rice density.
(d) Determination of in-situ water permeability of bituminous road surfacing or road base
layers by using the falling head (MARVIL) apparatus
The in-situ water permeability of asphalt surfacing and/or road base layers shall be determined using
the test method in SANS 3001-BT12. The permeability of a layer is an indication of the intensity of
interconnected voids in the layer that may be detrimental to the material due to oxidation of the binder
and/or ingress of water to the lower layers.
The apparatus for the test is shown in Figures 10100/3 to 6.
10110 Tests Relating To Chemical Stabilisation
(a) Test for cementitious binder content

The test method used for determining the cementitious binder content (lime or cement) of soils,
gravels or crushed stone mixed with a chemical stabilising agent shall be determined using
SANS 3001-GR58 back titration method.
(b) Canvas-patch test for the spreading rate of cementitious binder

The following method shall be used for determining the spreading rate of a chemical stabilising agent
where bulk distributors are used.
At least 10 clean canvas patches, each measuring 1m x 1m shall be placed flat on the road in selected
positions in relation to the bulk distributor’s track After the stabilising agent has been spread by the
bulk distributor the canvas patches shall be carefully lifted and all the material on the patches
transferred to a container and weighed. The total mass of stabilising agent on each patch is then
recorded and the average rate of application determined. Instead of canvas patches, flat metal trays
may be used for collecting the stabilising agent.
(c) Test for mix uniformity in chemically stabilised layers

Where required by the Engineer, the Contractor shall determine the mix uniformity in chemically
stabilised layers by means of unconfined compressive strength tests using SANS 3001-GR53.

The Contractor shall timeously make the necessary arrangements to take samples in accordance with
the requirements of the method used.
10111 Tests on Pavements

The following tests shall apply to pavements when specified for texture depth, straight-edge, and
rolling straight-edge.
(a) Determining the texture depth

The texture depth shall be determined by way of the sand-patch test as described in test method
SANS 3001-BT11.
(b) Straightedge test for surface irregularities on surfaces with a coarse surface texture
Where surface irregularities are measured on surfaces with a coarse surface texture such as grooved
concrete pavements, crushed-stone pavement layers, natural gravel road base, asphalt with rolled-in
chippings, surface treatments, seals and other like surfaces, the following procedure shall be followed:
 A metal wedge of 100 mm in length and 50 mm in width shall be constructed with a taper of
7.5 horizontal to 1.0 vertical and tapering to a feather edge (50 mm wide). Parallel lines
spaced at 7.5 mm intervals shall be engraved on the sloping face and numbered to indicate
the positions where the wedge is 1.0 mm. 2.0 mm, etc., thick.
 Where surface irregularities are measured, the 3.0 m straight-edge, which shall have sharp
right-angled corners at the bottom, shall be placed on the road and the thin edge of the wedge
inserted below the straight-edge from the front at the position where a surface irregularity is to
be measured. The size of the irregularity shall be determined in accordance with the mark to
which the wedge can be inserted without lifting the straight-edge. The width of the contact
plane of the straight edge shall be 18 mm ± 2 mm and its height shall be 80 mm ± 10 mm.
(c) Using the rolling straight-edge for measuring surface irregularities

The apparatus and testing method for this test shall be in accordance with testing method ST3 of
TMH6.
10112 Structural Tests
(a) Tests on elastomeric bearings
(i) General
Tests on elastomeric bearings shall be conducted in accordance with BS 5400 part 9.2, and the
bearings shall comply with the test requirements specified in the said specification.
(ii) Compression and shear-stiffness tests

When compression and shear-stiffness tests are conducted on sample bearers or on only a limited
number of bearers in a consignment, the stiffness values as determined by the tests shall be within
20% of the required values.
(b) Pre-stressed concrete: Testing pre-stressing steel, Anchorage assemblies, couplings

and grout
(i) General
Where so directed by the Engineer, the Contractor shall make arrangements for samples of the
materials he intends to use in the works to be tested by an independent testing authority. The cost of
testing pre-stressing steel, anchorage assemblies and couplings will be paid for as specified in sub-
clause 10103. Control tests on the viscosity and bleeding of grout will be regarded as part of the

Contractor's obligations under the Conditions of Contract and 10209 for process control and will not be
Materials represented by samples, which do not comply with the specified requirements, shall be
removed and replaced with suitable material.
(ii) Anchorages and couplers

Anchorage-s and couplers shall be tested in accordance with the requirements of sub-clause 8602(c).
The Anchorage s and couplers shall be assembled in accordance with their practical application on the
site where all the components necessary for anchoring shall be used, but excluding the ducts.
(iii) Pre-stressing steel

Pre-stressing steel shall be tested in accordance with the requirements of sub-clause 8602(b). Should
any test piece fail to comply with the requirements specified for the pre-stressing steel, the material
represented by that sample shall not be used without further testing and shall be replaced with
materials conforming to the Specifications if further testing confirms that they do not comply with the
Specifications.
(iv) Grout
The fluidity of grout shall be measured with a flow cone, immersion apparatus or viscometer. The
instrument shall be accurately calibrated in a laboratory so that the specified viscosity of the grout can
be controlled satisfactorily
The procedure for conducting the flow-cone test for measuring the fluidity of grout shall be as follows.
 Unless otherwise approved, the flow cone shall be as shown in figure 10100/7.
 Immediately after the grout has been mixed, the pre-wetted flow cone, which is held firmly with
its top rim in a level position, shall be filled with grout to the level indicated by the pre-set
pointer, whilst the bottom orifice is held closed with a finger.
 As soon as the required volume of grout (± 1 750 ml) is reached, the finger shall be released
to allow the grout to flow out freely through the bottom orifice. A stopwatch shall be used to
determine the flow time for emptying the cone, to the nearest second.
 The readings obtained during grouting shall be compared with the times determined in the
laboratory for grouts of the specified viscosities.
 The bleeding of grout shall be measured in a metal or glass container with an internal
diameter of approximately 100 mm and a height of approximately 120 mm. The grout and
water levels in the container shall be controlled with a metal bridge into which two adjustable
studs A and B are secured. See figure 10100/8 for details of the apparatus.
The procedure for determining the bleeding of grout shall be as follows:
 Studs A and B in the metal bridge shall be adjusted and locked so that the distance from the
lower tips of the studs to the bottom of the container will be approximately 100 mm and
107 mm respectively. The volumes VA and VB for the container at the respective levels of the
stud settings shall then be determined to the nearest millilitre.
 The container shall be filled with freshly mixed grout to a level where the grout will just touch
the tip of stud A, which points downwards. The bridge shall then be removed and the container
tightly sealed to prevent evaporation. The container shall then be stored at 20ºC and kept free
from vibrations for the entire duration of the test.
 Three hours after the grout has been mixed, the container shall be opened and the free
(bleed) water poured off. The bridge shall be placed over the container with the tip of stud B
pointing downwards and water poured onto the grout with a measuring apparatus until the

water level touches the tip of stud B. The volume of water added shall be determined to the
nearest millilitre and designated as ΔV.
 The percentage of bleeding shall be calculated from the formula:
{1-(VB – ΔV)/ VA } x 100
(c) Load test on foundation piles

The head of the test pile shall be exposed for checking position and slope. Where necessary, the head
shall be cut further back so as to expose a full bond length of main reinforcing steel, and a suitable pile
head slab for applying an axial load to the pile shall be cast. As an alternative, the head may be cut at
right angles and the load applied directly to the pile.
The test load shall be applied to the top of the pile with a hydraulic jack. Where more than one jack is
used to apply the load, all the jacks in the circuit shall be activated by the same pumping unit. The
jack(s) shall be so placed as to ensure that the load is applied axially.
The applied load shall be calculated in accordance with the hydraulic pressure, which shall be
monitored by two pressure meters in the circuit. The pressure meter shall be calibrated in Divisions not
exceeding 2% of the maximum pressure applied, and the range of the meters shall not exceed 150%
of the maximum pressure. The jack(s) and meters shall be calibrated by an approved testing
laboratory not more than four (4) weeks before the tests will commence.
The deflection of the pile head shall be measured with two scale rulers and two dial extensometers.
The scale rulers shall be fixed to the pile and placed on both sides of the pile on a diameter line, and
the dial extensometers shall be similarly placed but on a diameter line at right angles to that in which
the scale rulers have been mounted.
Level measurements shall be taken on the scale rulers, and reduced as a level mark to a similar scale
ruler placed at a distance from the test pile. All three scale rulers shall be calibrated in millimetres and
the level-indicating instrument shall be capable of taking readings to 0.5 mm. and approximate
readings of up to 0.1 mm.
The dial extensometers shall have a range of 50 mm, and shall be marked in 0.1 mm divisions to
enable measurements to 0.05 mm to be taken. The plungers of the extensometer shall rest on a
machined metal or glass surface.
The extensometers shall be supported by one or more beams kept in the shade. The supports for the
beams shall be so placed as to limit the effect of earth movements around the test pile on the
deflection readings.
The test load shall be applied in increments of 20% of the specified working load to a maximum test
load equal to twice the specified working load or the ultimate test load whichever is the smaller.
A load increment may not be applied before the subsidence or heave rate has stabilised at a rate of
not more than 0.10 mm in 20 minutes under the load applied.
After the loading has been completed the maximum test load shall be maintained until the movement
is less than 0.2 mm within a period of 24 hours. The load shall be removed in decrements of 20% of
the specified working load at intervals of not less than 20 minutes.
After the load has been removed the readings on both metres registering the movement of the pile
shall be recorded accurately to 0.1 mm. at intervals of 5, 10 and 20 minutes, and then every 30
minutes until the load is changed. The final recovery shall be recorded 24 hours after the maximum
test load has been removed.

During the test, the pile shall be loaded with up to 100% of the specified working load, and the load
shall then be removed. It shall then be loaded to the maximum test load after which the test load shall
be removed.
10113 Tests on Silicone Sealants

The following tests on silicone sealants will apply as determined in sub-clause 7102(f).
(a) Bond to cement mortar

Three briquettes, shaped in accordance with AASHTO T-132 and moisture-cured for at least 28 days
shall be sawn in half, cleaned and dried to a constant mass in an oven at a temperature of
110ºC ± 5ºC. After having cooled they shall be bonded with approximately 0.25 mm of silicone sealant
and tested with clamps, which comply with AASHTO T-132. They shall be tested under stress at a
loading rate of 7.62 mm/minute.
(b) Non-adhesive period

Prepare the specimens in a mould with an area exceeding that of the 6.35 mm thick brass weight
described below. Place a 30 g brass weight with dimensions of 41.28 mm x 25.4 mm x 3.18 mm on a
polyethylene strip applied to the sample after the specified curing period. After the weight has been
removed the polyethylene strip is removed by pulling it off at an angle of 90º to the mix and at a rate of
25.4 mm in 5 seconds. No material may adhere to the polyethylene while it is non-adhesive.
(c) Deformability and adhesion

Prepare concrete blocks of 25.4 mm x 25.4 mm x 76.2 mm in accordance with ASTM C-719. A sawn
surface is used as the bonding surface. Seal 50.8 mm of the block and leave 12.7 mm at each end of
the specimen unsealed. The sealant shall be 9.5 mm thick and 12.7 mm wide. Cure the specimen for
7 days in air at 25ºC ± 1.7ºC. and for 7 days in water at 25ºC ± 1.7ºC. Subject the sealant to
deformation in accordance with ASTM C-719. The ductility or compressive rate shall be 3.18 mm per
hour. One cycle is defined as extension to a width of 25.4 mm and returning to the initial width of
12.7 mm.
10114 Tests on Geotextiles and Geotextile-Soil Compatibility Tests

Where the term geotextile is used, it shall mean synthetic-fibre filter fabric.
(a) Puncture resistance tests on geotextiles
(i) Apparatus
See Figure 10100/9.
(ii) Clamping device

The specimen shall be positioned and clamped by means of a suitable clamping device that consists
of:
 A mounting-platen/supporting-sleeve assembly;
 An upper and a lower clamping ring provided with the necessary securing bolts, guide pins
and V-grooved concentric matching rings for securing the specimen.
(iii) mounting device

The specimen shall be positioned in the clamping rings, in a true plane, free from folds and stress, by
means of a suitable mounting device that consists of:
 A metal base plate at least 4 mm thick;

 A centring device secured to the base plate;

 A means of preventing the rotation of the upper clamping ring when the first two bolts are
tightened (two short sockets welded to the base plate will retain the bolt heads).
(iv) Cone assembly

The cone assembly shall consist of:
 A polished brass cone with the following dimensions:

 generating angle of cone = 45°.
 radius of point of cone = 0.5 mm.
 overall diameter = 50 mm.
 mass of falling assembly = 1kg:
 A means of retaining the point of the cone at a height of 500 mm above the specimen together
with a suitable release system.
(v) Measuring device

A suitable conical measuring device with a mass of 700 g ± 10 g and graduated from zero to 50 mm
diameter at 2 mm intervals over a length of 200 mm to measure the diameter of the hole formed in the
specimen. The device shall have a polished surface.
(vi) Marking and cutting stencil

A suitable metal stencil, with a handhold and studs to secure the stencil on the sample, capable of
accurately locating the position of bolt holes and pin holes on the specimen. The holes in the stencil
shall be 13 mm diameter (ie 2 mm larger than the holes to be cut into the specimen).
(vii) Felt pen and punch

 A 3 mm diameter felt-tipped pen.
 A punch capable of cutting 11 mm diameter holes in the specimen.
 A suitable cutting device
 A torque wrench
 Specimens
 Dimensions of specimens
Specimens shall be either 250 mm x 250 mm square; or circular with a diameter of 282 mm.
(viii) Number of specimens

At least 10 specimens shall be tested.
(ix) Preparation of specimens

The position of the holes on the specimen shall be marked through the stencil with the felt-tipped pen.
The specimens shall be cut by means of the metal stencil. With the aid of the stencil, mark on the
conditioned sample the positions of the required specimens, together with the positions of the holes
for bolts and locating pins. The specimens shall be set out in two rows equally spaced across the
width of the sample. The spacing of the specimens shall be as specified, except that the distance
between the two rows shall be 150 mm. Where the width of the sample does not allow all the
specimens to be set out in two rows, the number of rows shall be increased.
Carefully cut each specimen from the sample as specified. Centre the punch over the marked
positions and punch out the holes.
Maintain the conditioned specimens in the specified atmosphere. Test the specimens in the testing
atmosphere.

(x) Procedure
Place the lower clamping ring with bolts in position on the mounting device and carefully position the
specimen over the bolts and pins so as to ensure that the specimen is free from stress and is lying flat
on the mounting device. Position the upper clamping ring over the bolts and pins, and carefully lower
the ring onto the specimen. Secure the ring in position by tightening the nuts to a torque of 30 Nm.
(xi) Testing
Ensure that the mounting-platen supporting-sleeve assembly is central with the line of the fall of the
cone.
Place the clamping-ring assembly on the supporting cylinder.
Operate the cone-release system.
Carefully remove the cone from the specimen and measure the diameter of the hole formed in the
specimen with the measuring device. The device shall be gently lowered vertically, by hand, into the
hole formed in the specimen until penetration under its own mass stops. The diameter of the hole is
taken as the graduation nearest to the line of contact between the device and the geotextile.
Note: It is advisable to pack the inside of the supporting cylinder with a resilient material of sufficient thickness to
prevent damage to the cone in the event of complete penetration of the specimen.
(xii) Calculation and reporting

Record the diameter of the hole formed for each specimen and calculate the average diameter of the
holes for the sample.
Round off the results correct to 2 mm.
(xiii) Reporting
Report the value of the hole diameter for each specimen and the average diameter for the sample.
(xiv) Information sheet

An approved information sheet shall be completed in full for each geotextile.
(b) Permeability reduction (flow test)
(i) Water supply

 A supply of water from an overhead tank with a constant head of 1 000 mm ± 25 mm above
the geotextile sample shall be provided.
 A permeameter with a suitable means of mounting to ensure that the permeameter remains in
a vertical position throughout the test. The permeameter shall consist of the following:
o Two 90 mm internal diameter perspex cylinders: the bottom cylinder with a recess for
the support mesh and a breather hole.
o Two perspex end caps with inlet/outlet nozzles: machined as shown in Figure
10100/10 to fit over the cylinders and to allow air bubbles to escape through the inlet
nozzle; the upper cap provided with a bleeding hole.
o Three brass rods and nuts (wing nuts).
o Brass or stainless steel mesh with 2.67 mm openings (standard soil sieve).
(ii) Cutting device

A means of cutting out a circular specimen with a diameter of at least 110 mm.
(iii) Miscellaneous equipment

 Containers with capacity of at least 5 litres.
 A riffler with 25.0 mm openings.

 A soil-test sieve with 13.2 mm openings.

 A balance to weigh up to 1 kg, to an accuracy of 1 g.
 Stopwatch.
 Silicone grease.
 Pans.
(iv) Number of specimens

Conduct one test for each soil/geotextile combination.
(v) Geotextile specimens

Mark and cut the required number of specimens and maintain them in the standard atmosphere until
they are tested.
(vi) Soil samples

Sieve the oven-dried soil through a 13.2 mm sieve and discard the material larger than 13.2 mm. Riffle
the remaining soil to obtain specimens of 1 000 g ± 5 g. Place the specimens in sample bags and label
them.
(vii) Procedure
 Place the geotextile specimen between the two cylinders on top of the mesh. Apply silicone
grease to ensure that water does not leak out between the two cylinders.
 Mix the amount of water required to bring the soil sample to optimum moisture content (OMC).
With dispersive soils, friable mudstones and heavy clays remoulding often gives an
impermeable soil mass. In such cases this step shall be omitted and the soil sample shall be
placed dry.
 Place the soil sample on top of the geotextile and smooth the surface without compacting the
soil.
 Place the perspex end caps in position and fasten the rods and nuts. Place the assembled
permeameter in its mounting.
 Close the outlet and the breather hole in the lower cylinder and slowly fill the entire cylinder
with water from the top. Care must be taken not to disturb the surface of the soil sample. This
can be done by using a small-diameter pipe with a spray nozzle, which is inserted through the
top inlet to a height just above the soil surface. Fill the permeameter to the top of the inlet
nozzle, remove the small-diameter pipe, and connect the hose from the constant-head tank.
Remove any entrapped air bubbles through the inlet nozzle and the bleeding hole.
 Open the outlet nozzle and breather hole in the lower cylinder and record the time at the
beginning of the test.
 The first outflow measurement shall be taken between 1 minute and 5 minutes after the
beginning of the test. Outflow is measured by way of a container and stopwatch. The
container shall be placed under the outflow and the time to fill the 5 litre container, or the
amount of flow that occurs in 30 minutes recorded, whichever occurs first. It is not important
that exactly 5 litres or 30 minutes be used, but the time and volume shall be recorded
accurately. Record the following with each outflow measurement:
o Date and time (hours and minutes)
3
o Flow volume (1,000 mm = 1 ml) - Calculate flow in m /s
o Flow time (minutes and seconds)
o Height of the sample (soil + geotextile) in mm
o Height of the water head above the bottom of the geotextile in mm (ensure that this
height remains at 1,000 mm ± 25 mm)

o The discolouration or otherwise of the water at the outlet.

 Outflow measurements shall be taken at the beginning of the test (1 minute to 5 minutes after
the outlet has been opened) and thereafter at least once a day. The test shall be continued for
at least 400 hours (17 days).
(viii) Calculations
Calculate the permeability coefficient (K) for each outflow measurement, as follows:
K = Q/i.A (mm/s), where

3
Q = outflow (mm /s)
i = hydraulic gradient = water head above geotextile (mm) / sample height (mm)
A = cross-section area (mm²) (= 6 362 mm² for 90 mm diameter)
The permeability reduction factor, K400, is determined at the end of the test as follows:
3
K400 = 100 x (K at 400 hours)/K at beginning of test (l/m )
If an outflow measurement has not been taken at exactly 400 hours, K at 400 hours may be
determined by linear interpolation.
The degree of permeability reduction is determined by means of Figure 10100/11.
(ix) Information sheet

An approved information sheet shall be completed in full for each geotextile. Failure to provide the
required information may be taken as sufficient motivation for the geotextile to be disqualified
10115 Classifying the Tests

For the purposes of this section tests are defined as indicated herein.
(a) Ordinary Tests

Ordinary tests are tests that are constantly conducted by the Contractor on a regular basis in terms of
the Conditions of Contract and section 10100 for which no specified Pay Items have been provided,
and which include the following, inter alia:
 Tests for determining the properties of all natural materials provided by the Contractor for use
in the works such as sand, stone, water, soil and gravel.
 Tests for determining the properties of processed natural materials purchased or produced on
the site by the Contractor, such as aggregate for concrete, asphalt mixes and surface seals.
 Tests for determining the properties of products such as concrete and asphalt produced
specially for use on the works by the Contractor, or purchased from commercial producers or
sub-contractors.
 Tests on completed elements of construction such as embankments pavement layers, and
concrete structures for establishing compliance with the specified properties.
(b) Special Tests

Special tests are tests that have to be conducted by the Contractor only at the specific request of the
Engineer, and include the following:
 Tests on commercial products such as cement, lime, paint, bituminous materials, pipes,
valves, cranes and bridge bearings. The requirements are specified as a whole or in part by
reference being made to the specifications of a standards organisation such as the SABS.
 Special tests on structures or elements of structures to determine their efficacy, for which clear
provision for payment has been made in the Specifications and the Bills of Quantities.
 Any test requested by the Engineer purely for purposes of acceptance control. Such tests,
however, will not be classified as a special test if the test is requested because the Contractor
has neglected to conduct sufficient or proper tests in terms of the Conditions of Contract and
with a view to submitting the result to the Engineer for his approval of completed work or
materials.
(c) Payment
Payment will be made under the Pay Items of Clause 10117 only in regard to special tests. Payment
for ordinary tests shall be included in the rates tendered by the Contractor for the items of work to
which the ordinary tests relate.
10116 Testing of Construction Water
(a) Compressive strength test

The average 28-day strength of three mortar cubes made with Ordinary Portland Cement and the
water that is to be tested shall be at least 90% of that of three similar cubes made with water of known
purity.
Additional tests shall be carried out to ensure that the setting time of the cement is not adversely
affected by impurities.
(b) Inorganic impurities criteria

The water used to manufacture concrete shall comply with the criteria in Table 10116/1 unless
otherwise approved by the Engineer.
Table 10116/1: Criteria for Inorganic Impurities in Water Used To Manufacture Concrete
Characteristic Criteria Test Method

pH 4.5 - 8.5 SABS method 113
Reinforced concrete: 400 ppm
Sulphates Pre-stressed concrete: 400 ppm SABS method 212
Mass concrete: 1,000 ppm
Chlorides 500 ppm SABS method 202
Conductivity @ 25 OC 330 mS/m SABS method 213
Total Dissolved Solids @ 18 Reinforced concrete: 1,500 ppm
SABS method 84
OC Mass concrete: 3,000 ppm
Alkali, Carbonates and
1,000 ppm SABS method 837
Bicarbonates
Sugar Negative
Chemical Oxidation
Organic impurities 300 ppm (applicable if pH < 5
Demand

The costs of compliance with the standards are deemed to be incidental to work items and the Bidder
is to include these costs in the item rates in the Bill of Quantities. No separate payment shall be
admissible on account of compliance of the stipulations of this Division.

Figure 10100/1: Weathering Apparatus

Figure 10100/2: Visual Classification for Mudrocks and Shale Aggregate Soundness Test

Figure 10100/3: Marvil Apparatus
Figure 10100/4: Grease Ring for Marvil Test

Figure 10100/5: Placing of Prestik sealant for Marvil Apparatus
Figure 10100/6: Placing Of Plaster Of Paris for Marvil Apparatus (if required)

Figure 10100/7: Flow Cone for Measuring the Fluidity of Grout

Figure 10100/8: Metal or Glass Container for measuring the Bleeding of Grout

Figure 10100/9: Cone Assembly and Measuring Device for Puncture Resistance Test on
Geotextiles

Figure 10100/10: Permeameter for Permeability Production Tests (Flow Tests)

Figure 10100/11: Permeability Reduction Criteria

Division 10200: Quality Control (Scheme 1)
10201 Scope
This section describes one scheme for determining compliance with certain requirements of the
specifications in regard to the properties of materials and workmanship, by means of measurements
and tests and by applying statistical judgement plans.
It also covers the requirements in regard to the control to be exercised by the Contractor to monitor the
quality of his work and materials, and the routine tests and inspection to be carried out by the
Engineer.
The provisions of this Division shall apply to this Contract insofar as they do not supersede compliance
specified in other Divisions of the Technical Specification.
10202 Judgment Plans: General

Certain requirements and limit values are set out in the Specifications in regard to the properties of
materials and workmanship to be supplied. Tests shall be conducted and measurements taken to
control the relevant properties of the workmanship and materials supplied, and the results of such
tests and measurements shall be assessed on the basis of the prescribed criteria for compliance with
the specified requirements.
Two methods are available for assessing compliance. For certain properties statistical judgement
plans are prescribed for assessing the test results, and, where no such statistical judgement plan has
been prescribed, materials and workmanship shall be fully in accordance with the specified
requirements and limit values.
In this section two types of statistical judgement plans are used, as follows:
 Judgement plan A is used for judging measurement of the levels and thicknesses of
pavement layers. In accordance with this method the compliance of the individual results is
determined only in respect to the specified requirements: the variability of test results is not
computed.
 Judgement plan B is used for judging measurements of in-situ densities, the strengths of
concrete, and certain other properties. In this judgement plan the variability of the values of
tests is calculated and applied where acceptance limits for sample means are determined.
Despite acceptance of those properties judged by these statistical methods, the materials or work
submitted will be rejected when other properties (which are not controlled by statistical methods) fail to
comply with the requirements of the Specifications; or where there are other causes for rejection such
as obviously defective workmanship or excessively variable properties; visible signs of poor
workmanship; and similar considerations which constitute sufficient grounds for rejecting the work
without any further testing.
The Engineer shall be entitled to assess separately any specified portion of a lot if, in his opinion, it
exhibits significant deviations as compared with the remainder of the lot.
In order to avoid changing the risk of the Contractor or the Employer, the statistical judgement plans
shall be strictly adhered to in all cases where they are used; and decisions based on these plans shall
not be altered. The validity of the decisions made on the basis of these judgement plans shall not be
disputed on the grounds of statistical theory; or a specified or implied producer’s risk; or unjust on the
grounds of enrichment.

10203 Definitions
For the purposes of this section the following words and symbols shall have the following meanings:
(a) Lot
A lot is a sizeable portion of work or quantity of material, which is assessed as a unit for the purposes
of quality control, and which is selected to represent material or work produced by essentially the
same process and from essentially the same materials.
(b) Random sample

A random sample is a group of "n" test measurements at "n" separate test positions or on "n" sample
portions obtained from the lot in an unbiased manner.
Random sampling shall mean stratified random sampling, unless inconsistent with the context.
(c) Sample mean ( xn )
is the arithmetic mean of a set of "n" test results constituting the sample.
x n
(d) Sample standard deviation ( S n )

The sample standard deviation ( S n ) is defined by
=
 x  n x  n1  , where:
2 2
n
S n
is the sample mean

x n
x is the value of an individual sample portion, i.e. an individual test result or measurement.
n is the sample size (ie the number of individual test results or measurements).
(e) Specification limit (Ls)

The Specification limit is the limit value of the property of any product outside which not more than a
certain specified percentage (  ) of the population of values representing an acceptable product
property is allowed to lie. The specification limit may be a single lower limit L s, or a single upper limit
L's, or a double limit consisting of a lower limit Ls and an upper limit L's.
(f) Acceptance limit (La)

The Acceptance limit is the limit value of the sample mean within which the lot will be accepted. For a
lower-limit specification this acceptance limit is denoted by L a. For an upper-limit specification, this
acceptance limit is denoted by L'a. For a double limit specification, the lower and upper limits are
denoted by La and L'a respectively.

(g) Conditional acceptance

Conditional acceptance is the acceptance of a lot at reduced payment in lieu of rejection.
Conditional acceptance shall be subject to the provisions of Clause 10208.
(h) Rejection limit (Lr)

The Rejection limit is the limit value of the sample mean outside which conditional acceptance cannot
be considered. It may be a lower limit Lr or an upper limit L'r.
(i) Payment reduction factor (fr)

The Payment reduction factor is the factor by which payment at contract rates shall be multiplied for
calculating the payment for conditionally accepted work.
(j) Outliers
Where, in a sample one, or more test results differ significantly from the other values obtained, this
difference could be ascribed to an assignable cause, in which case such test result shall be regarded
as an outlier and disregarded when assessing the lot.
To determine whether or not a test result is an outlier, the procedure given in sub-clause 10204(d)
shall be adopted.
(k) Factors ka, kad, kr, and krd

These factors are used for calculating the various judgement limits, as follows:
(i) Acceptance limits (La and L'a)

ka is used for determining the acceptance limits for single-limit specifications
kad is used for determining the acceptance limits for double-limit specifications.
(ii) Rejection limits (Lr and L'r):

Only when specified in the Particular Specifications that rejection limits shall be determined in
accordance with the provisions of Clause 10211, the factors kr and krd shall be used.
kr is used for determining the rejection limits in the case of a single-limit specification.
krd is used for determining the rejection limits in the case of a double-limit specification.
The factors ka, kad, kr and krd shall apply to both a first submission and a resubmission.
(iii) Ø (%)
Ø is the maximum percentage of a statistical population of values of a product property permitted to lie
outside the specification limits where the product may still be regarded as being acceptable. Values for
Ø may be obtained from Table 10206/3.
(l) First submission

The submission of a lot for approval will be classified as a first submission when submitted for the first
time or when submitted for a second time due to the properties of the first and the second sets of test
values differing significantly. In this case, the second set of test values shall be regarded as the first
submission in terms of sub-clause 10204(e).
(m) Resubmission
The submission of a lot for approval for a second time shall be classified as a resubmission should it
be regarded as a resubmission in terms of sub-clause 10204(e), because the properties of the first
and second sets of test values do not differ significantly.
(n) Rehabilitation and repair work

For rehabilitation or repair works the definitions of lot, lot size and sample size shall be as specified in
the Particular Specifications, or as directed by the Engineer.
(a) Determining lot size
(i) Road construction layers

The lot size shall normally be a section compacted in one process where essentially the same
materials and construction equipment have been used. Where production is on a continuous basis, a
lot shall normally mean the product of one day's work and shall not exceed the product of two full days'
work. However, a lot of any smaller size may be ordered by the Engineer where:
 The properties under investigation exhibit abnormal local variation within the normal lot size;
 An area is obviously of a different quality than the rest;
 The rate of production is very high.
For rehabilitation or repair work the lot size shall be as specified in the Particular Specifications, or as
determined by the Engineer.
(ii) Concrete
The lot size shall be determined by the Engineer, with due regard to the size and the type of structure
in which the concrete is placed, the specific portion of the structure and the total quantity of concrete
placed in a day. The lot sizes in concrete structures could therefore vary considerably, and, particularly
in the case of small structures, it could be necessary to combine samples of the same grade of
concrete from different structures, provided that the concrete is obtained from the same concrete plant
and is cast in the same period.
(iii) Other
In other cases, as for example in material stockpiles where the definition of a lot in accordance with
sub-clause 10203(a) does not apply directly the Engineer will determine lot sizes in each case
according to the circumstances.
(b) Random sampling

When any lot is tested, whether a normal sized lot or an isolated section, which clearly exhibits an
abnormal variation of the property under consideration, all samples shall be taken in a stratified
random pattern. For this purpose use shall be made of tables of random numbers, and the instructions
in publication TMH5, Sampling for Road Construction Materials, shall be followed.
(c) Sample sizes

For purposes of acceptance control, the Engineer shall, in advance, determine sample size "n". No
sample size may be smaller than that given in Sub-clause 10206(a) and Table 10206/2. For
rehabilitation or repair work the sample size shall be as specified in the Particular Specifications or
prescribed by the Engineer.
(d) Outliers
Test results shall be scanned for possible outliers. Where a test result deviates greatly from the
remainder in a lot, it shall, if possible, be re-examined by further testing and, if there is reasonable
evidence to suggest that the test result is erroneous, it shall be regarded as an outlier, rejected, and
replaced with a fresh test result.

Where repeating a test or re-examining a test result is impossible, Method 1 shall be used for
identifying outliers for all work, except road base and bituminous pavement and surfacing layers.
Method 2 shall be used for identifying outliers for road base and bituminous pavement and surfacing
layers.
(i) Method 1
Calculate the value of To from: To = x  x  S
o n n
Where:
x n
and S n
are respectively the sample arithmetic mean and standard deviation, and
x o
is the value of the test result differing most from the mean.
Compare the value of To with the value of T for the applicable value of "n", from Table 10204/1.
If the absolute value of To is greater than T, then x o

is an outlier.
Table 10204/1: Critical Values (Except Road Base and Asphalt Mixes)
Number of observations Critical value

(n) (T)
4 1.46
5 1.67
6 1.82
7 1.94
8 2.03
9 2.11
10 2.18
11 2.23
12 2.29
13 2.33
14 2.37
15 2.41
16 2.44
17 2.47
18 2.50
19 2.53
20 2.56
Where S n
is very small, it may be the cause for a value being wrongly classified as an outlier. For
this purpose a minimum value S n

(min) shall be determined for S n
as follows:
2
( x0.99: n - 1) / (n - 1)
S n
(min) = , where:
2 2
x 0.99
: n -1 = x 0.99
for (n - 1) degrees of freedom as obtained from Table 10204/2; and
S n
= mean value for S n
for the particular property as determined by records of previous work.
Every outlier shall be deleted, and, if possible, be replaced with a new random test value.

Table 10204/2: Values of x 0.99 Distribution
2 2 2
(n - 1) (n - 1) (n - 1)
x 0.99 x 0.99 x 0.99
1 0.000157 11 3.053 21 8.897
2 0.0201 12 3.571 22 9.542
3 0.115 13 4.107 23 10.196
4 0.297 14 4.660 24 10.856
5 0.554 15 5.229 25 11.524
6 0.872 16 5.812 26 12.198
7 1.239 17 6.408 27 12.879
8 1.646 18 7.015 28 13.565
9 2.088 19 7.633 29 14.256
10 2.558 20 8.260 30 14.953
(ii) Method 2
In the case of road base and asphalt work the following procedure shall be used for identifying outliers
where it is impossible to repeat a test or to reinvestigate a test result:
Calculate the absolute value Co from: Co = / o - x x n

/
Where x o
represents the possible outlier.
Compare Co with the critical value C = C0.01; nσ
Where σ is the standard deviation of the population derived from historical data.
If the absolute value Co > C, the test result x o

shall be regarded as an outlier and shall be excluded
from the sample.
The critical values for different values of "n" are given in tables 10204/3 and 10204/4 for the different
product properties.
Table 10204/3: Outlier Test for Road base: Critical Values

CRITICAL VALUES C
For For sieve size (mm)
n
percentage For PI
26.5 19.0 13.2 4.75 2.00 0.425 0.075
compaction
4 4.1 6.1 8.5 8.5 7.3 5.6 3.6 3.2 2.4
5 4.4 6.4 9.0 9.0 7.7 5.9 3.9 3.3 2.6
6 4.6 6.7 9.4 9.4 8.0 6.2 4.0 3.5 2.7
7 4.7 6.9 9.7 9.7 8.3 6.3 4.1 3.6 2.8
8 4.8 7.1 9.9 9.9 8.5 6.5 4.2 3.7 2.8
8 4.9 7.2 10.1 10.1 8.6 6.6 4.3 3.7 2.9
10 4.9 7.3 10.2 10.2 8.7 6.7 4.4 3.8 2.9

Table 10204/4: Outlier Test for Asphalt: Critical Values C
n CRITICAL VALUES C
For density For bitumen content For voids in mix
4 3.2 0.4 2.3
5 3.3 0.5 2.4
6 3.5 0.5 2.5
7 3.6 0.5 2.6
Every outlier shall be discarded and replaced by another random test value. The sample mean
x n
and the sample standard deviation S n

shall then be recalculated. If an outlier cannot be replaced, the
sample mean and standard deviation shall be calculated on the basis of the remaining test results.
The final number of test results used in the assessment after the elimination of an outlier shall never
be less than four.
(e) Resubmission
Where a lot has been accepted conditionally or has been rejected, the Engineer may agree to its
resubmission for approval if:
 It has been reworked and the Engineer is satisfied that a proper attempt was made to improve
the properties which were unacceptable; or
 Where, in his opinion, there are valid technical reasons therefor.
In both cases a fresh sample shall be taken, and a fresh (second) set of test values determined. The
first and second sets of test values shall then be compared with each other to determine whether their
properties differ significantly.
Where in the opinion of the Engineer a significant difference does occur, the submission of the lot shall
be regarded as a first submission and be assessed as such, and only the second set of test values
shall then be used for this purpose.
Where in the opinion of the Engineer no significant difference occurs, the submission of the lot shall be
regarded and assessed as a resubmission, which will mean, inter alia, that the first and second sets of
test values shall be combined for purposes of assessment.
In order to be able to determine theoretically whether there is a significant difference between the two
sets of test values (suffixes a and b), the Fisher F-test shall be conducted, and, if necessary, also the
t-test, all as described herein.
(i) The Fisher F-test

The Fisher F-test is conducted as follows:
Calculate the value of F   S k , where:

2 2
S g
S g
= the greater value of S a and S b
S k = smaller value of S a and S b
The value of F 0.05

, U , U k is obtained from table 10204/5 where:
g
U g
= sample size minus one, from the sample with the larger standard deviation.
U k
= sample size minus one, from the sample with the smaller standard deviation.

Where F > F 0.5 , U , U k a significant difference occurs theoretically between the two sets of
g
test values, but where F < F 0.5 , U , U k the difference is not necessarily significant, and the t-
g
test shall also be conducted with a view to obtaining a decision.
(ii) The t-test

The t-test is conducted as follows:
Calculate
S n  1S  n  1S  n  n  2
a
2
a b
2
b a b
Then calculate
t  x  x  S 1/ n
a b a
 1 / nb 
Where x x
a b
is the absolute value of the difference between
x a
and
x and is always positive.
b
Determine the degrees of liberty U  na  nb  2
The value of t 0.05

,U is obtained from table 10204/6.
Where t t 0.05
,U a significant difference occurs between the two sets of results. If t t 0.05
,U there
is no significant difference.

Table 10204/5: Values of F Distribution (Σ = 0.05)
Ug 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 24 26 28 30
Uk
1 161.4 200.0 216.0 225.0 230.0 234.0 237.0 239.0 241.0 242.0 243.0 244.0 245.0 245.0 246.0 246.0 247.0 247.0 248.0 248.0 249.0 249.0 249.0 250.0 250.0
2 18.51 19.00 19.20 19.20 19.30 19.30 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.40 19.50 19.50 19.50 19.50 19.50
3 10.13 9.55 9.28 9.12 9.01 8.94 8.89 8.85 8.81 8.79 8.76 8.74 8.73 8.71 8.70 8.69 8.68 8.67 8.67 8.66 8.65 8.64 8.63 8.62 8.62
4 7.71 6.94 6.59 6.39 6.26 6.16 6.09 6.04 6.00 5.96 5.94 5.91 5.98 5.87 5.86 5.84 5.83 5.82 5.81 5.80 5.79 5.77 5.76 5.75 5.75
5 6.61 5.79 5.41 5.19 5.05 4.95 4.88 4.82 4.77 4.74 4.70 4.68 4.66 4.64 4.62 4.60 4.59 4.58 4.57 4.56 4.54 4.53 4.52 4.50 4.50
6 5.99 5.14 4.76 4.53 4.39 4.28 4.21 4.15 4.10 4.06 4.03 4.00 3.98 3.96 3.94 3.92 3.91 3.90 3.88 3.87 3.86 3.84 3.83 3.82 3.81
7 5.59 4.74 4.35 4.12 3.97 3.87 3.79 3.73 3.68 3.64 3.60 3.57 3.55 3.53 3.51 3.49 3.48 3.47 3.46 3.44 3.43 3.41 3.40 3.39 3.38
8 5.32 4.46 4.07 3.84 3.69 3.58 3.50 3.44 3.39 3.35 3.31 3.28 3.26 3.24 3.22 3.20 3.19 3.17 3.16 3.15 3.13 3.12 3.10 3.09 3.08
9 5.12 4.26 3.86 3.63 3.48 3.37 3.29 3.23 3.18 3.14 3.10 3.07 3.05 3.03 3.01 2.99 2.97 2.96 2.95 2.94 2.92 2.90 2.89 2.87 2.86
10 4.96 4.10 3.71 3.48 3.33 3.22 3.14 3.07 3.02 2.98 2.94 2.91 2.89 2.86 2.85 2.83 2.81 2.80 2.78 2.77 2.75 2.74 2.72 .71 2.70
11 4.84 3.98 3.59 3.36 3.20 3.09 3.01 2.95 2.90 2.85 2.82 2.79 2.76 2.74 2.72 2.70 2.69 2.67 2.66 2.65 2.63 2.61 2.59 2.58 2.57
12 4.75 3.89 3.49 3.26 3.11 3.00 2.91 2.85 2.80 2.75 2.72 2.69 2.66 2.64 2.62 2.60 2.58 2.57 2.56 2.54 2.52 2.51 2.49 2.48 2.47
13 4.67 3.81 3.41 3.18 3.03 2.92 2.83 2.77 2.71 2.67 2.63 2.60 2.58 2.55 2.53 2.51 2.50 2.48 2.47 2.46 2.44 2.42 2.41 2.39 2.38
14 4.60 3.74 3.34 3.11 2.96 2.85 2.76 2.70 2.65 2.60 2.57 2.53 2.51 2.48 2.46 2.44 2.43 2.41 2.40 2.39 2.37 2.35 2.33 2.32 .31
15 4.54 3.68 3.29 3.06 2.90 2.79 2.71 2.64 2.59 2.54 2.51 2.48 2.45 2.42 2.40 2.38 2.37 2.35 2.34 2.33 2.31 2.29 2.27 2.26 2.25
16 4.49 3.63 3.24 3.01 2.85 2.74 2.66 2.59 2.54 2.49 2.46 2.42 2.40 2.37 2.35 2.33 2.32 2.30 2.29 2.28 2.25 2.24 2.22 2.21 2.19
17 4.45 3.59 3.20 2.96 2.81 2.70 2.61 2.55 2.49 2.45 2.41 2.38 2.35 2.33 2.31 2.29 2.27 2.26 2.24 2.23 2.21 2.19 2.17 2.16 2.15
18 4.41 3.55 3.16 2.93 2.77 2.66 2.58 2.51 2.46 2.41 2.37 2.34 2.31 2.29 2.27 2.25 2.23 2.22 2.20 2.19 2.17 2.15 2.13 2.12 2.11
19 4.38 3.52 3.13 2.90 2.74 2.63 2.54 2.48 2.42 2.38 2.34 2.31 2.28 2.26 2.23 2.21 2.20 2.18 2.17 2.16 2.13 2.11 2.10 2.08 2.07
20 4.35 3.49 3.10 2.87 2.71 2.60 2.51 2.45 2.39 2.35 2.31 2.28 2.25 2.22 2.20 2.18 2.17 2.15 2.14 2.12 2.10 2.08 2.07 2.05 2.04
21 4.32 3.47 3.07 2.84 2.68 2.57 2.49 2.42 2.37 2.32 2.28 2.25 2.22 2.20 2.18 2.16 2.14 2.12 2.11 2.10 2.07 2.05 2.04 2.02 2.01
22 4.30 3.44 3.05 2.82 2.66 2.55 2.46 2.40 2.34 2.30 2.26 2.23 2.20 2.17 2.15 2.13 2.11 2.10 2.08 2.07 2.05 2.03 2.01 2.00 1.98
23 4.28 3.42 3.03 2.80 2.64 2.53 2.44 2.37 2.32 2.27 2.23 2.20 2.18 2.15 2.13 2.11 2.09 2.07 2.06 2.05 2.02 2.00 1.99 .97 1.96
24 4.26 3.40 3.01 2.78 2.62 2.51 2.42 2.36 2.30 2.25 2.21 2.18 2.15 2.13 2.11 2.09 2.07 2.05 2.04 2.03 2.00 1.98 1.97 1.95 1.94
25 4.24 3.39 2.99 2.76 2.60 2.49 2.40 2.34 2.28 2.24 2.20 2.16 2.14 2.11 2.09 2.07 2.05 2.04 2.02 2.01 1.98 1.96 1.95 1.93 1.92
26 4.23 3.37 2.98 2.74 2.59 2.47 2.39 2.32 2.27 2.22 2.18 2.15 2.12 2.09 2.07 2.05 2.03 2.02 2.00 1.99 1.97 1.95 1.93 1.91 1.90
27 4.21 3.35 2.96 2.73 2.57 2.46 2.37 2.31 2.25 2.20 2.17 2.13 2.10 2.08 2.06 2.04 2.02 2.00 1.99 1.97 1.95 1.93 1.91 1.90 1.88
28 4.20 3.34 2.95 2.71 2.56 2.45 2.36 2.29 2.24 2.19 2.15 2.12 2.09 2.06 2.04 2.02 2.00 1.99 1.97 1.96 1.93 1.91 1.90 1.88 1.87
29 4.18 3.33 2.93 2.70 2.55 2.43 2.35 2.28 2.22 2.18 2.14 2.10 2.08 2.05 2.03 2.01 1.99 1.97 1.96 1.94 1.92 1.90 1.88 1.87 1.85
30 4.17 3.32 2.92 2.69 2.53 2.42 2.33 2.27 2.21 2.16 2.13 2.09 2.06 2.04 2.01 1.99 1.98 1.96 1.95 1.93 1.91 1.89 1.87 1.85 1.8

Table 10204/6: Values for T-Distribution (Σ = 0.05)
U t U t U t
1 6.3138 11 1.7959 21 1.7207
2 2.9200 12 1.7823 22 1.7171
3 2.3534 13 1.7709 23 1.7139
4 2.1318 14 1.7613 24 1.7109
5 2.0150 15 1.7530 25 1.7081
6 1.9432 16 1.7459 26 1.7056
7 1.8946 17 1.7396 27 1.7033
8 1.8595 18 1.7341 28 1.7011
9 1.8331 19 1.7291 29 1.6991
10 1.8125 20 1.7247 30 1.6973
10205 Judgement Plan A (Surface Levels and Layer Thicknesses)

Surface levels and layer thicknesses shall be judged in accordance with the procedure herein.
(a) Taking the levels

Level measurements shall be taken in a random pattern, before and after a layer has been constructed; and
levels shall be taken at exactly the same point before and after construction. Layer thicknesses will then be
determined as the difference between the pre- and post-construction levels but may be supplemented by
determinations made by means of holes made in the layer.
The number of measurements of layer thicknesses shall be at least 30, and that of surface levels at least 50.
Larger sample sizes will give more reliable results.
In the case of asphalt layers, the Engineer may require that layer thicknesses be determined only by means
of measurements taken on drilled cores, in which case the minimum number of cores shall be 20 per lot and
not 30.
For rehabilitation or repair work the number of measurements shall be as specified in the Particular
Specifications or as directed by the Engineer.
(b) Calculating the deviations

Compute the difference between the specified level or thickness and the actual level or thickness. Compute
the mean thickness of the layer.
(c) Identifying outliers

Check this work by re-measuring any results that may possibly be defective.
(d) Assessing the results

The following criteria will apply when results are assessed:
(i) Surface levels

The lot will comply with the requirements specified for surface levels if at least 90% of all surface levels are
within the H90 tolerance specified in each case, before any level corrections are made.
Individual spots, where the surface level deviates by more than the H max tolerance specified in each case,
shall be repaired to bring them to within the H90 tolerance.
(ii) Layer thickness

The layer will comply with the requirements specified for layer thickness if at least 90% of all thickness
measurements taken are equal to or thicker than the specified thickness, minus the D90 tolerance specified in
the relevant section, before any thickness corrections are made; and the mean layer thickness for the lot is
not less than the specified layer thickness minus the D ave tolerances specified in each case.
Page10000-780 Ethiopian Roads Authority

Individual spots, where the actual thickness is less than the specified thickness minus the D max tolerance
specified in each case, shall be locally repaired to bring them within the D 90 tolerance.
10206 Judgement Plan B

The characteristic properties to be controlled in accordance with this judgement scheme are as shown in
Table 10206/1.
Table 10206/1: Characteristic Properties: Judgement Plan B

Structure Characteristic
Gravel pavement layers Relative compaction
Crushed-stone base or sub-base Relative compaction
Relative compaction
Asphalt base and surfacing Binder content of mix
Voids in mix
Chemically stabilised layers Stabilising agent content
Concrete Compressive strength
The procedure to be followed when assessing the above properties shall be as follows:
(a) Taking samples and testing the properties

Determine the sample size (n) by taking into consideration the minimum sample sizes given in
Table 10206/2, and take the samples in a stratified random pattern as specified in sub-clause 10204(b).
Conduct the appropriate tests.
For rehabilitation or repair work the sample size shall be as specified in the Particular Specifications or as
(b) Identifying outliers

Outliers shall be identified, not taken into account, and, if possible, replaced with fresh test values, all as
prescribed in sub-clause 10204(d).
Table 10206/2: Minimum Sample Sizes For Concrete (Structural)

3
Size of lot (m ) Minimum sample size (n)
0 - 20 4
21 – 40 6
41 – 70 9
71 – 100 12
101 – 150 14
> 150 16
(c) Calculating standard deviation and the mean of sample values
Use the sample results for calculating the standard deviation S n

and the mean
x n
of the sample values in
accordance with definitions in Clause 10203.
Where it is a resubmission (as defined in Clause 10203), the first and second sets of sample results shall be
used for determining a combined sample mean

x ab
, standard deviation S ab
and sample size.

(d) Determining the judgement limits

All judgement limits shall be computed to three decimal figures.
(e) First submission

The acceptance limits La and L'a are calculated in accordance with the formulas given below in the case of a
first submission (as defined in Clause 10203).
n ab
 na  nb
x ab
 n x  n x  n  n 
a a b b a b
S ab n  1S a  nb  1S b  na

 
 a
2 2
xab xa  n xab xb   n  n  1
2
b
2
a b
where:
subscript “a” refers to the first set of test values,
subscript “b” refers to the second set of test values
subscript “ab” refers to the combined properties.
For a lower-limit specification
La = LS + Sn.ka
Accept the lot if the sample mean is equal to or greater than the acceptance limit La, otherwise reject the
x n
lot.
 For an upper-limit specification

L'a = L's - Sn.ka
Accept the lot if the sample mean is equal to or less than the acceptance limit L'a, otherwise reject the
x n
lot.
 For a double-limit specification calculate
La = LS + Sn.kad
L'a = L's - Sn.kad
Accept the lot if the sample mean falls between the lower acceptance limit La and the upper acceptance
x n
limit L'a or is equal to either one, otherwise reject the lot.
Where a lot has been rejected, it may nevertheless be considered for conditional acceptance in terms of
Clause 10208.
(f) Resubmission
Where a lot is resubmitted for approval in terms of sub-clause 10204(e) the acceptance limits are determined
as follows:
 For a single-limit specification
La = LS + Sab.ka
L'a = L's – Sab.ka

Accept the lot if xab ≥ La in the case of a lower-limit specification and if xab ≤ L'a in the case of an upper limit
specification, otherwise reject the lot.
 For a double-limit specification
La = LS + Sab.kad
L'a = L's – Sab.kad
Accept the lot if La ≤ xab ≤ L'a. If not, reject the lot.
The values of ka and kad used in the above cases shall agree with the sample size nab.
Where a resubmitted lot is rejected, it may nevertheless be considered for conditional acceptance in terms of
Clause 10208.
The evaluation of a resubmitted lot shall be final and binding on both Employer and Contractor. The
provisions of this section shall be strictly complied with.
Where a resubmitted lot is rejected, the Contractor shall be obliged to bear the costs of the additional tests
conducted on the resubmitted lot.
(g) Values of constants

The values of the specification limits Ls and L's are given in the relevant sections of the specifications and
are briefly summarised in table 10206/3. The minimum sample size "n" and the maximum percentage of
defectives (  ) in an acceptable product are also given in the table.
The values of ka and kad are given in Tables 10206/4 and 10206/5.
Table 10206/3: Values of Constants N, Ls, L's and Ø
Ls L's
Minimum
(Lower (Upper Ø
Material Properties sample
specification specification (%)
size (n)
limit) limit)
Selected subgrade Relative compaction 4 90%, 93% or 95% - 15
Sub-base Relative compaction 6 95% or 97% - 15
98% and if
Gravel road base Relative compaction 6 - 15
stabilised, 97%
Crushed stone:
See Divisions
sub-base or road Relative compaction 6 - 15
5100 & 5200
base
Relative compaction 6 15
Asphalt base or
Binder content 6 See note 1 See note 1 15
surfacing
Voids 4 15
Chemically stabilised Cementitious binder
10 See note 2 See note 2 10
layers content
Strength concrete Compressive strength (28 See table
See notes 3 5
(structural) days) 10200/8
Compressive strength (28 See sub-clause
Pavement concrete 6 5
days) 7102(j)(i)
Notes:
1. Specification limits for asphalt base or surfacing:
 Density Ls = (97 - % of voids in approved production mix) % of theoretical maximum density (see
Clause 6410)
 Binder content (conventional and homogeneous modified binders)
 For continuously and semi-gap graded mixes
Ls = specified binder content - 0.30% binder

L's = specified binder content + 0.30% binder
 For gap graded mixes. slurry seals and non-homogeneous modified binders
Ls = specified binder content - 0.40% binder
L's = specified binder content + 0.40% binder
 Voids
Ls = specified values - 1.5 percentage points
L's = specified values + 1.5 percentage points
2. Specification limits for cementitious-binder content

 Ls = 70% of the specified cementitious-binder content or as ordered by the Engineer.
3. Specification limits for compressive strength of concrete

 Ls = the specified 28-day cube characteristic strength (see Clause 8404, e g. for Class C 25/40
concrete, Ls = 25 MPa.)
Table 10206/4: Values of Ka (Single Limits)
Sample ka
size (n) Ø = 5% Ø = 10% Ø = 15%
4 0.747 0.445 0.220
5 0.821 0.520 0.300
6 0.878 0.576 0.358
7 0.923 0.620 0.403
8 0.961 0.656 0.440
9 0.993 0.687 0.470
10 1.020 0.713 0.496
12 1.065 0.755 0.538
14 1.101 0.789 0.571
16 1.131 0.817 0.598
18 1.155 0.840 0.620
20 1.177 0.860 0.640
Table 10206/5: Values of Kad (Double Limits)
Sample kad
size (n) Ø = 5% Ø = 10% Ø = 15% Ø = 20%
4 0.605 0.299 0.061 -0.161
5 0.691 0.390 0.163 -0.038
6 0.756 0.456 0.235 0.043
7 0.809 0.509 0.290 0.103
8 0.852 0.551 0.334 0.149
9 0.888 0.587 0.370 0.188
10 0.919 0.617 0.401 0.219
12 0.971 0.666 0.451 0.271
14 1.012 0.706 0.489 0.310
16 1.046 0.738 0.521 0.342
18 1.074 0.764 0.547 0.369
20 1.099 0.787 0.570 0.391
(h) Requirements for non-structural concrete

Where any concrete sections or parts are indicated by the Engineer or on the Drawings as being non-
structural, the statistical judgement scheme shall not apply, and only compliance with the specified
characteristic strength will be required. Compliance with the specified characteristic strength means that the
mean strength of the sample shall be at least equal to the specified characteristic strength, and no single test
result may be lower than the specified characteristic strength minus 5 MPa.

10207 Controlling More Than One Property

Where more than one property of a lot is to be controlled, the lot shall be accepted if all the properties
comply with the specified requirements; but the lot shall be rejected if one or more of the properties do not
comply with the specified requirements; or the lot may be conditionally accepted subject to the requirements
of Clause 10208.
10208 Conditional Acceptance
(a) General
Where a lot is rejected under statistical judgement plan B but the test results are such that the lot complies
with the requirements for conditional acceptance specified hereafter, the Engineer may accept the lot
conditionally; that is, the lot may be accepted at reduced payment in lieu of complete rejection, provided that:
 Conditional acceptance shall be in the sole discretion of the Engineer and not an option which may
be exercised by the Contractor or a right the Contractor may claim;
 The lot is approved in respect of all other requirements not judged by a statistical judgement plan;
 The Contractor shall have the option to remove and reinstate at his own cost conditionally accepted
work with work which complies with the requirements for acceptance at full payment;
 Conditional acceptance and the corresponding reduced payment shall apply only in respect of the
work and properties listed in sub-clause 10208(b) below.
(b) Properties to which conditional acceptance applies

Conditional acceptance may be applied in respect of the properties listed in Table 10208/1.
Table 10208/1: Properties for which conditional acceptance may be applied

Property Structure
(i) Asphalt base or surfacing

(ii) Chemically stabilised layers
Relative compaction
(iii) Plant mixed paver laid layers
(See note 2)
Bitumen binder content Asphalt base or surfacing

Voids in mix Asphalt base or surfacing
Cementitious binder content or
Chemically stabilised layers
strength requirements
All strength concrete except concrete
28-day-cube compressive strength
pavements (See note 1)
Notes:
1. See sub-clause 7120(f) for details regarding reduced payment in the case of inadequate concrete
strength or layer thickness in concrete pavements.
2. Crushed stone layers shall not be subject to conditional acceptance, but, where compaction to 88% of
apparent density is specified but has not been obtained, the Engineer in his sole discretion may accept
the layer against payment at the rate for compaction to 86% of apparent density, provided that the layer
complies with all the requirements specified for a crushed stone layer compacted to 86% of apparent
density.
(The same provisions shall apply where a specified compaction of 102% of Mod AASHTO density cannot be attained, but 100% of
density can be attained.)

(c) Criteria for conditional acceptance

Any lot which does not comply with the requirements for acceptance plan B may be conditionally accepted
should the value of the sample mean lie within the rejection limits given in Table 10208/2.
x n
The payment reduction factor shall be calculated in accordance with the following formula:
For conditional acceptance at a lower limit
fr = 0.67 + 0.3( -Lr)/( La - Lr)

x n
For conditional acceptance at an upper limit
fr = 0.67 + 0.3 (L'r - )/( L'r - L'a)

x n
See Clause 10203 for the meaning of the symbols.
Where so required in the Particular Specifications, the rejection limits shall be determined in accordance with
the requirements of Clause 10211 instead of Table 10208/2.

Table 10208/2: Rejection Limits (Lr and L'r) For Sample Mean ( )
x n
Property Structure Rejection limits (Lr and L'r)

(a) Chemically stabilised layers in Lr = (La -2.000)% of relative compaction
Relative compaction accordance with sections 3500 or 3700
L'r = (L'a -1.000)% of relative compaction
(b) Asphalt base or surfacing
Concrete compressive All strength concrete Lr = 0.85 La
strength (excepting that in pavements)
Bituminous binder Lr = (La - 0.200)% binder
Asphalt
content (%) L'r = (L'a + 0.200)% binder
Lr = (La - 0.300)% voids
Voids in mix (%) Asphalt
L'r = (L'a + 0.300)% voids
Cementitious binder Lr = 0.800 La
content
(d) Applying the payment-reduction factor

The payment-reduction factor shall be applied to the following payment items as relevant and described in
the specifications.
 Stabilised layers: Items 42.01, 42.02, 46.01, 46.02, 46.05, 46.06, 46.07, 46.08 and 46.09.
 Asphalt base and surfacing: Items 64.01, 64.02, 64.03, 64.09, 64.10, 64.11, 64.12, 64.13 and
64.16.
 Concrete: Items 84.01, 84.02 and 84.03. (No reduction will apply to payment items for formwork,
reinforcing and pre-stressing tendons).
 Concrete pavement layers mixed in a central mixing plant and placed by paver: Items 71.02, 71.03,
71.12, 71.13, 71.14 and 71.15.
Where payment items are introduced into the Particular Specifications or are changed in the Bill of
Quantities, the payment reduction factor shall apply to the payment items corresponding to the payment
items mentioned above.
Where a lot is conditionally accepted in regard to more than one property, the payment-reduction factor for
each property shall be computed and the factor that gives the largest reduction shall be applied; except in
the case of concrete pavement when the provisions of sub-clause 7120(f) shall apply.
10209 Process Control by the Contractor

The onus rests with the Contractor to produce work which conforms in quality and accuracy of detail to all the
requirements of the Specifications and Drawings, and the Contractor shall, at his own expense, institute a
quality control system and provide experienced engineers, foremen, surveyors, materials technicians, other
technicians and other technical staff, together with all transport, instrumentation and equipment to ensure
adequate supervision and positive control of the works at all times.
The Contractor shall conduct tests, or have them conducted continually on a regular basis, to check the
properties of natural materials and processed natural materials and of products manufactured on the site
such as concrete and asphalt mixes. Although not a requirement for the Contractor to conduct regular tests
on any commercially produced products such as cement, bitumen, steel and pipes, the Contractor shall
remain fully responsible for any defective material or equipment provided by him. Similarly, the quality of all
elements of the works shall be checked on a regular basis so as to ensure compliance with the requirements
of the specifications.
The intensity of control and of tests to be conducted by the Contractor shall be adequate to ensure that
proper control is being exercised.

Where any natural materials or products made from natural materials are supplied, and upon completion of
each element of the construction work, the Contractor shall test and check such materials, products and/or
elements for compliance with the specified requirements and shall submit his results to the Engineer for
approval. Such submission shall include all his measurements and test results and shall furnish adequate
proof of compliance with the specified requirements.
No specific Pay Items are provided as compensation for the above obligations, including the provision of all
samples to be delivered to the Engineer; the repair of places from which samples were taken; and the
provision of the necessary personnel and testing apparatus and facilities; for which compensation shall be
included in the tendered rates of the Contractor for the various items of work to which these obligations
apply.
The Contractor’s attention is also drawn to the provisions of Clauses 10209 or 10308 in regard to instituting
specific process-control systems.
For continuous concrete and asphalt-production processes, the Engineer may order the Contractor to
augment the above-mentioned control system by introducing a system of process control for monitoring the
various properties to be controlled. The specific system used shall be subject to the Engineer's approval, and
the attention of the Contractor is drawn to the systems described in Clause 4.4 of TRH 5.
The Contractor shall take immediate steps to rectify any deviation from the specified requirements indicated
by his process-control system, and the Engineer shall have the right to inspect, and be given all details of
tests and testing procedures, in order to satisfy himself that the Contractor is implementing an adequate
process-control system.
10210 Routine Tests and Inspection by the Engineer

The Engineer will inspect and test materials and completed work at regular intervals for compliance with the
specified requirements and, where applicable, the various judgement plans specified will be applied. The
testing frequencies and sample and lot sizes for routine testing shall be at the Engineer's discretion.
All sections of completed work shall be submitted to the Engineer for routine inspection and testing. and the
Contractor shall not cover up or construct any work on top of sections of completed work before being
advised by the Engineer of the outcome of his testing and inspection. The Contractor shall make
arrangements for the submission of work for testing in a manner which will afford the Engineer reasonable
opportunity for inspecting and testing the work.
10211 Determining Rejection Limits in accordance with Statistical Criteria

Where required in the Particular Specifications that the rejection limits be determined in accordance with
statistical criteria such as TRH5, it shall be done as indicated herein.
(a) For a single-limit specification

First submission
Lr = Ls + Sn.kr
L'r = L's - Sn.kr
The lot shall be accepted conditionally where ≥ Lr in the case of a lower-limit specification, or where
x n x n
≤ L'r in the case of an upper-limit specification, otherwise reject the lot.

(b) For a double-limit specification

Lr = Ls + Sab.krd
L'r = L's - Sab.krd
The lot shall be conditionally accepted where ≥ Lr and ≤ L'r , otherwise reject the lot.
x n
The values of kr and krd are given in Tables 10211/1 and 10211/2.
Table 10211/1: Values of Kr (Single-Limit Specification)
Sample kr
size (n) Ø = 5% Ø = 10% Ø = 15%
4 0.446 0.123 -0.148
5 0.547 0.238 -0.004
6 0.622 0.320 0.089
7 0.682 0.382 0.158
8 0.732 0.432 0.211
9 0.773 0.474 0.255
10 0.809 0.509 0.292
12 0.867 0.567 0.357
14 0.914 0.612 0.397
16 0.952 0.649 0.434
18 0.985 0.680 0.465
20 1.013 0.707 0.491
Table 10211/2: VALUES OF krd (DOUBLE-LIMIT SPECIFICATION)
Sample krd
size (n) Ø = 5% Ø = 10% Ø = 15% Ø = 20%
4 0.338 -0.007 -0.324 -0.708
5 0.451 0.132 -0.130 -0.389
6 0.534 0.226 -0.016 -0.241
7 0.600 0.296 0.065 -0.144
8 0.653 0.352 0.126 -0.073
9 0.698 0.398 0.176 -0.018
10 0.736 0.437 0.217 0.027
12 0.800 0.500 0.283 0.098
14 0.850 0.550 0.334 0.152
16 0.891 0.590 0.375 0.194
18 0.926 0.624 0.409 0.229
20 0.956 0.653 0.438 0.259

Division 10300: Quality Control (Scheme 2)
10301 Scope
This section describes one scheme used for determining compliance with certain requirements of the
specifications in regard to the properties of materials and workmanship, by means of tests and
measurements and by applying statistical judgement plans.
It also covers the requirements in regard to the control to be exercised by the Contractor for monitoring the
quality of his work and materials, and the routine tests and inspections to be carried out by the Engineer.
10302 Judgement Plans: General

Certain requirements and limit values are set out in the Specifications in regard to the properties of materials
and workmanship to be supplied. Tests shall be conducted and measurements taken to control the relevant
properties of the workmanship and materials supplied, and the results of such tests and measurements shall
be assessed on the basis of the prescribed criteria for compliance with the specified requirements.
Wherever possible, acceptance criteria shall be determined by way of statistical principles described in this
section. Wherever impracticable and where no statistical judgement criteria have been prescribed, there
shall be full compliance with the requirements and limit values in the Specifications.
Despite acceptance of those properties judged by these statistical methods, the materials or work submitted
shall be rejected when other properties (which are not controlled by statistical methods) fail to comply with
the requirements of the Specifications; or where there are other causes for rejection such as obviously
defective workmanship or excessively variable properties, visible signs of poor workmanship, and similar
considerations which constitute sufficient grounds for rejecting the work without any further testing.
The Engineer shall be entitled to assess separately any specified portion of a lot if, in his opinion, it exhibits
significant deviations as compared with the remainder of the lot.
In order to avoid changing the risk of the Contractor or the Employer, the statistical judgement plans shall be
strictly adhered to in all cases where they are used, and decisions based on these plans shall not be altered.
The validity of the decisions made on the basis of these judgement plans shall not be disputed on the
grounds of statistical theory or a specified or implied producer’s risk, or unjust on the grounds of enrichment.
10303 Definitions
For the purposes of this section the following definitions of terms and symbols shall apply:
(a) Lot
A lot is a sizeable portion of work or quantity of material which is assessed as a unit for the purposes of
quality control, and selected to represent material or work produced by essentially the same process and
from essentially the same materials.
(b) Random sample

A random sample is a group of "n" test measurements at "n" separate test positions or on "n" sample
portions obtained from the lot in an unbiased manner.
Random sampling shall mean stratified random sampling, unless inconsistent with the context
(c) Sample mean ( xn )

is the arithmetic mean of a set of "n" test results constituting the sample.
x n

(d) Specification limit (Ls)

This is the limit value of the property of any product outside which not more than a specified percentage (Ø)
of the population of values representing an acceptable product property is allowed to lie. The specification
limit may be a single lower limit Ls, or a single upper limit L's or a double limit consisting of a lower limit Ls and
an upper limit L's.
(e) Acceptance limit for sample mean (La)

This is the limit value of a product property within which the sample mean shall lie for a product to be
acceptable.
For a lower-limit specification, the acceptance limit is denoted by La. For an upper-limit specification, this
acceptance limit is denoted by L'a. For a double-limit specification, the lower and upper limits are denoted by
La and L'a.
(f) Acceptance limits for individual test values Le

These are the limit values of a product property within which the sample values representing a product shall
lie for the product to be acceptable.
The limit values will depend on the sample sizes "n" and may be a lower limit L e, an upper limit L'e, or double
limits Le and L'e.
(g) Conditional acceptance

This is the acceptance of a lot at reduced payment in lieu of rejection. Conditional acceptance shall be
subject to the provisions of Clause 10307.
(h) Outliers
Where, in a sample, one or more test results differ significantly from the other values obtained, this difference
could be ascribed to an assignable cause, in which case such test result shall be regarded as an outlier and
disregarded when assessing the lot.
To determine whether or not a test result is an outlier, the method given in sub-clause 10304(d) shall be
adopted.
(i) First submission

The submission of a lot for approval will be classified as a first submission when actually submitted for the
first time or when submitted for a second time due to the properties of the first and the second set of test
values differing significantly. In this case a second set of test values which shall be regarded as a first
submission in terms of sub-clause 10304(e).
(j) Resubmission
The submission of a lot for approval for a second time shall be classified as a resubmission should it be
regarded as a resubmission in terms of sub-clause 10304(e), as the properties of the first and second sets of
test values do not differ significantly.
(k) Payment reduction factor (fr)

This is the factor by which payment at contract rates shall be multiplied for calculating payment for
conditionally accepted work.
(l) Rehabilitation and repair work

For rehabilitation or repair works, the definitions for lot, lot size and sample size shall be as specified in the
Particular Specifications or as directed by the Engineer.

(a) Determining the lot size
(i) Road construction layers

The lot size shall normally be a section compacted in one process where essentially the same materials and
construction equipment have been used. Where production is on a continuous basis, a lot shall normally
mean the product of one day's work and shall not exceed the product of two full days' work. However, a lot of
any smaller size may be ordered by the Engineer where:
 The properties under investigation exhibit abnormal local variation within the normal lot size;
 An area is obviously of a different quality than the rest;
 The rate of production is very high.
For rehabilitation or repair work the lot size shall be as specified in the Particular Specifications, or as
determined by the Engineer.
(ii) Concrete
The lot size shall be determined by the Engineer, with due regard to the size and the type of structure in
which the concrete is placed, the specific portion of the structure, and the total quantity of concrete placed in
a day. The lot sizes in concrete structures may therefore vary considerably, and, particularly in the case of
small structures, it may be necessary to combine samples of the same grade of concrete from different
structures, provided that the concrete has been obtained from the same concrete plant in the same period.
(iii) Other
In other cases, as for example in material stockpiles where the definition of a lot in accordance with sub-
clause 10303(a) does not apply directly, the Engineer will determine lot sizes in each case according to the
circumstances.
(b) Random sampling

When any lot is tested, whether a normally sized lot or an isolated section which clearly exhibits an abnormal
variation of the properties under consideration, all samples shall be taken in a stratified random pattern. For
this purpose use shall be made of tables of random numbers, and the instructions in publication TMH5,
Sampling for Road Construction Materials, shall be followed.
(c) Sample sizes

For purposes of acceptance control, the Engineer will, in advance, determine sample size "n". No sample
size may be smaller than that given in Clause 10305. For rehabilitation or repair work the sample size shall
be as specified in the Particular Specifications or prescribed by the Engineer.
(d) Outliers
Test results shall be scanned for possible outliers. Where a test result deviates greatly from the remainder in
a lot, it shall, if possible, be re-examined by further testing, and, if there is reasonable evidence to suggest
that the test result is erroneous, it shall be regarded as an outlier, rejected, and replaced with a fresh test
result.
Where repeating a test or re-examining a test result is impossible, method 1 of this sub-clause shall be used
for identifying outliers for all work except road base and bituminous pavement and surfacing layers. Method 2
shall be used for identifying outliers for road base and bituminous pavement and surfacing layers.
(i) Method 1
Calculate the value of To from: To = x  x  S
o n n
, where

and S are respectively the sample arithmetic mean and standard deviation, and
x n n
x o
is the value of the test result differing most from the mean.
Compare the value of To with the value of T for the applicable value of "n", from the table 10304/1.
If the absolute value of To is greater than T, than x o

is an outlier.
Every outlier shall be discarded, and, if possible, be replaced with a new random test value.
Table 10304/1: Critical Values
No of observations (n) Critical values (T)

4 1.46
5 1.67
6 1.82
7 1.94
8 2.03
9 2.11
10 2.18
11 2.23
12 2.29
13 2.33
14 2.37
15 2.41
16 2.44
17 2.47
18 2.50
19 2.53
20 2.56
(ii) Method 2
In the case of road base and bituminous pavement and surfacing layers the following procedure shall be
used for identifying outliers where it is impossible to repeat a test or to reinvestigate a test result:
Calculate the absolute value Co from Co = / o - x x n

/ , where x o
represents the possible outlier.
Compare Co with the critical value C = C0.01; nσ
Where σ is the standard deviation of the population derived from historical data.
If the absolute value Co > C, then the test result x o

shall be regarded as an outlier and shall be excluded
from the sample.
The critical values for different values of "n" are given in Tables 10304/2 and 10304/3 for the different product
properties.
Every outlier shall be discarded and replaced by another random test value. The sample mean and the
x n
sample standard deviation S n

shall then be recalculated, if an outlier cannot be replaced, the sample mean
and standard deviation shall be calculated on the basis of the remaining test results. The final number of test
results used in the assessment after the elimination of an outlier shall never be less than four (4).

Table 10304/2: Outlier Test for Road base: Critical Values C
n For For sieve size (mm) For PI

percentage 26.5 19.0 13.2 4.75 2.00 0.425 0.075
compaction
4 4.1 6.1 8.5 8.5 7.3 5.6 3.8 3.2 2.4
5 4.4 6.4 9.0 9.0 7.7 5.9 3.9 3.3 2.6
6 4.6 6.7 9.4 9.4 8.0 6.2 4.0 3.5 2.7
7 4.7 6.9 9.7 9.7 8.3 6.3 4.1 3.6 2.8
8 4.8 7.1 9.9 9.9 8.5 6.5 4.2 3.7 2.8
9 4.9 7.2 10.1 10.1 8.6 6.6 4.3 3.7 2.9
10 4.9 7.3 10.2 10.2 8.7 6.7 4.4 3.8 2.9
Table 10304/3: Outlier Test for Asphalt: Critical Values C
n CRITICAL VALUES C
For density For bitumen content For voids in mix
4 3.2 0.4 2.3
5 3.3 0.5 2.4
6 3.5 0.5 2.5
7 3.6 0.5 2.6
(e) Resubmission
Where a lot has been accepted conditionally or has been rejected, the Engineer may agree to its
resubmission for approval if:
 It has been reworked and the Engineer is satisfied that a proper attempt was made to improve the
properties which were unacceptable; or
 Where, in his opinion there are valid technical reasons therefor.
In both cases a fresh sample shall be taken, and a fresh (second) set of test values determined.
The first and second sets of test values shall then be compared with each other to determine whether their
properties differ significantly.
Where in the opinion of the Engineer a significant difference does occur, the submission of the lot shall be
regarded as a first submission and assessed as such, and only the second set of test values shall then be
used for this purpose.
Where in the opinion of the Engineer no significant difference occurs, the submission of the lot shall be
regarded and assessed as a resubmission. Where a lot is resubmitted, it shall be assessed on the same
basis as a first submission, except that the original and the second set of sample results shall be combined
for purposes of assessment.
10305 Procedures
The statistical judgement procedures described herein will apply to the corresponding product properties for
purposes of acceptance control.
Note: For rehabilitation or repair work the number of measurements, tests or samples for acceptance control in respect
of the product properties specified in Sub-clauses (a) to (f) of this Clause shall be as specified in the Particular
Specifications or prescribed by the Engineer.
(a) Surface levels of fills and pavement layers

At least fifty (50) surface level measurements shall be made according to a stratified random pattern for each
lot of completed layer work, and the deviation from the corresponding specified level shall be determined.
Outliers shall be identified and examined.

The lot will be considered to comply with the requirements in respect of surface levels if, before any repair
work is undertaken, at least 90% of the level measurements show a deviation from the specified levels which
is smaller than the H90 tolerance specified for the layer under evaluation.
Isolated spots, where the surface levels deviate by more than the appropriate H max tolerance of the specified
levels shall be repaired to bring the deviation to within the H 90 tolerance.
(b) Layer thicknesses of pavement layers

At least thirty (30), but preferably more, layer thicknesses shall be determined in accordance with a stratified
random pattern for each lot of completed layer work. Layer thicknesses shall be determined by means of
level measurements taken before and after construction of the layer in exactly the same position, but may be
augmented by thicknesses measurements taken by means of holes made in the layer.
In the case of asphalt layers, the Engineer may require thickness determinations to be made only by means
of measurements on drilled cores, in which case the minimum number of cores per lot shall be twenty (20).
Outliers shall be identified, eliminated, and, if possible, replaced.
The lot will be considered to comply with the requirements for layer thicknesses if:
 At least 90% of all the thickness measurements taken before any thickness repairs are made is
equal to or greater than the specified thickness, minus the D 90 tolerances specified in the appropriate
section; and
 The mean layer thickness of the lot is not less than the specified thickness, minus the D mean
tolerance.
Isolated spots where the actual thickness is less than the specified thickness less the D max tolerance shall be
repaired so as to fall within the D90 tolerance.
(c) Relative compaction of pavement layers

At least four (4) relative density determinations shall be taken in the case of Capping Layers and at least six
(6) in the case of all other pavement layers in accordance with a random pattern. After outliers have been
identified and replaced, compliance with the specified density requirements shall be determined as follows:
 The sample mean shall be not less than the acceptance limit (La) for the sample mean as given
x n
in Table 10305/1, and no single test value shall be lower than the acceptance limit (Le) for single
values.
(d) Cementitious binder content of stabilised layers and uniformity of mix

At least fifty (50) samples shall be taken according to a random pattern and their cementitious-binder content
determined.
As described in sub-clause 10110(a), due allowance shall be made for the presence, in the material to be
stabilised, of minerals, which may affect the test results.
The quantity of cementitious binder in the mixed material, determined as specified, shall fall within the
following limits:
 The mean cementitious-binder content shall be not less than 91% of the specified binder content.
 The cementitious binder content in at least 75% of the samples shall be at least 70% of the specified
binder content.
The requirements for uniformity of the mix shall apply only on condition that the variation of these
adjustments fall within the limits specified in sub-clause 10110(a).
(e) Binder content of asphalt

At least four (4) specimens of asphalt shall be taken in a random pattern and the binder content determined.
After determining the sample mean, the lot shall be assessed using the following criteria:
The binder content of asphalt mixes shall not deviate from the specified binder content by more than the
value given in Table 10305/2.

Table 10305/1: Acceptance Limits in Respect of Compaction

Minimum average relative compaction for the Minimum value for any single test for the
Required
Layer Test Method following sample sizes following sample sizes
Compaction
4 5 6 7 8 9 4 5 6 7 8 9
90% AASHTO T-180 density 90.1 90.4 90.6 90.7 90.9 91.0 86.4 86.2 86.0 85.9 85.8 85.7
93% AASHTO T-180 density 93.1 93.4 93.6 93.7 93.9 94.0 89.4 89.2 89.0 88.9 88.8 88.7
Capping Layers
95% AASHTO T-180 density 95.1 95.4 95.6 95.7 95.9 96.0 91.4 91.2 91.0 90.9 90.8 90.7
100% AASHTO T-180 density 100.1 100.4 100.6 100.8 100.9 101.0 96.4 96.2 96.0 95.9 95.8 95.7
95% AASHTO T-180 density 95.1 95.4 95.6 95.7 95.9 96.0 91.4 91.2 91.0 90.9 90.8 90.7
Sub-base 96% AASHTO T-180 density 96.1 96.4 96.6 96.7 96.9 97.0 92.4 92.2 92.0 91.9 91.8 91.7
97% AASHTO T-180 density 97.1 97.4 97.6 97.7 97.9 98.0 93.4 93.2 93.0 92.9 92.8 92.7
97% AASHTO T-180 density 97.1 97.4 97.6 97.7 97.9 98.0 93.4 93.2 93.0 92.9 92.8 92.7
Gravel road base 98% AASHTO T-180 density 98.1 98.4 98.6 98.7 98.9 99.0 94.4 94.2 94.0 93.9 93.8 93.7
100% AASHTO T-180 density 100.1 100.4 100.6 100.8 100.9 101.0 96.4 96.2 96.0 95.9 95.8 95.7
Crushed-stone road base 98% AASHTO T-180 density 98.1 98.4 98.6 98.7 98.9 99.0 94.4 94.2 94.0 93.9 93.8 93.7
(GB 1) 100% AASHTO T-180 density 100.1 100.4 100.6 100.8 100.9 101.0 96.4 96.2 96.0 95.9 95.8 95.7
Asphalt base and (97-% voids in mix) % of

100% 100.1 100.3 100.5 100.6 100.7 100.8 97.1 96.9 96.8 96.7 96.6 96.5
surfacing theoretical density
Shoulders and wearing

93% AASHTO T-180 density 93.2 93.6 93.8 94.0 94.2 94.3 87.9 87.6 87.4 87.2 87.0 86.9
course
Plant mixed pavement

100% AASHTO T-180 density 100.1 100.3 100.5 100.7 100.8 100.9 96.4 96.2 96.0 95.9 95.8 95.7
layers (section 3700)

Table 10305/2: Acceptance Limits for Bituminous Binder Content

Maximum deviation from the sample mean Maximum deviation of any single test value
from the sample binder content from the specified binder content
Sample (%of binder) (% of binder)
size Gap-graded and non- Continuous, semi-gap-
(number) homogeneous graded and open- Gap-graded and
Continuous and
modified binder graded conventional semi-gap-graded
open-graded mixes
mixes and slurry and homogeneous mixes
seals modified binder mixes
2 0.51 0.37 0.76 0.54
3 0.44 0.33 0.81 0.58
4 0.41 0.30 0.84 0.60
5 0.38 0.29 0.87 0.62
6 0.36 0.27 0.89 0.64
7 0.35 0.25 0.91 0.65
8 0.33 0.25 0.92 0.66
(f) Concrete: 28-day cube compressive strength

At least the minimum number of samples given in table 10305/4 shall be obtained according to a
random pattern and test cubes made according to an approved method and tested for compressive
strength after 28 days.
Outliers shall be identified and eliminated.
Compliance with the requirements for the characteristic strength of the lot shall be assessed according
to the following criteria:
≥ Ls + ∆A, where:
x n
= a mean value of the 28-day cube compressive strength tests

x n
Ls = characteristic strength specified in the indicated concrete-class
∆A = the applicable value given in table 10305/3
x ≥ Ls - ∆B, where:
n
x = the 28-day cube compressive strength of a single test

n
∆B = the applicable value given in Table 10305/3.
Table 10305/3: Acceptance Factors for Concrete Strength

Sample size ∆A ∆B
(n) (MPa) (MPa)
3 0.5 3.9
4 1.1 4.2
5 1.4 4.5
6 1.7 4.7
7 1.9 4.9
8 2.1 5.0
9 2.2 5.2
10 2.3 5.3
11 2.4 5.4
12 2.5 5.5
13 2.8 5.6
14 2.7 5.7
15 2.7 5.8

Table 10305/4: Minimum Sample Sizes for Strength Concrete (Structural)

3
Volume of lot (m ) Minimum sample size
0-20 4
21-40 6
41-70 9
71-100 12
101-150 14
> 150 16
10306 Controlling more than one Property

Where more than one property of a lot is being controlled, the lot shall be accepted if all the properties
comply with the specified requirements. But if one or more of the properties do not comply with the
requirements, the lot shall be rejected, or it may be conditionally accepted subject to the provisions of
Clause10307.
10307 Conditional Acceptance
(a) General
Where a lot is rejected under a statistical judgement plan described in this section but the test results
are such that the lot complies with the requirements for conditional acceptance specified hereafter, the
Engineer may accept the lot conditionally, that is, the lot may be accepted at reduced payment in lieu
of complete rejection, provided that:
 Conditional acceptance shall be in the sole discretion of the Engineer and is not an option
which may be exercised by the Contractor or a right he may claim;
 The lot is approved in respect of all other requirements not judged by a statistical judgement
plan:
 The Contractor shall have the option, at his own cost, to remove work which has been
conditionally accepted and replace it with work which complies with the requirements for
acceptance at full payment;
 Conditional acceptance and the corresponding reduced payment shall apply only in respect of
the work and properties listed in sub-clause 10307(b) below.
(b) Properties to which conditional acceptance applies

Conditional acceptance may be applied in respect of the properties of structures listed below in Table
10307/1.
The same provision shall apply for crushed stone (GB 1) base where a specified density of 100% of
density cannot be attained but 98% of density has in fact been attained.i
Table 10307/1: Properties to which Conditional Acceptance may apply

Property Structure
(i) Asphalt base or surfacing
Relative compaction (ii) Chemically stabilised layers
(iii) Plant mixed paver laid layers
Bituminous-binder content Asphalt base or surfacing
Cementitious-binder content or
strength requirements
28-day cube compressive All structural concrete (excepting concrete pavements)
strength

(c) Criteria for conditional acceptance

In terms of the respective judgement plans relating to the properties to which conditional acceptance
applies, two requirements shall always apply, viz one in relation to the sample mean ( ). and one In
x n
relation to individual test values x . A lot may be conditionally accepted when it complies with one of
n
the two requirements for acceptance, but not with the second requirement provided that it complies
with the requirements for conditional acceptance in relation to the second requirement. There are
therefore always two cases:
(i) Case 1
The lot complies with the requirement for sample mean, but not in all cases with the requirement for
individual test values.
The lot may be accepted conditionally, subject to the following additional conditions:
(1) in regard to the relative compaction of pavement layers, the bituminous-binder content of asphalt
mixes and the concrete cube compressive strength, not more than one test value shall fail to comply
with the requirements of individual test values.
(2) In regard to the cementitious-binder content, the binder content may be below 70% of the
specified binder content in not more than 25% of cases.
(ii) Case 2
The lot complies with the requirements for individual test values but not with the requirements for
sample mean.
The lot may be accepted conditionally on condition that the sample mean lies within the rejection
x n
limits given in Table 10307/2.

Table 10307/2: Rejection Limits (Lr and L'r) for the Sample Mean ( x n )
Property Structure Rejection limits (Lr and L'r)

Relative compaction (a) Chemically stabilised layers in Lr = (La - 2.000)% relative compaction
accordance with section 3500 or 3700
(b) Asphalt base or surfacing
Lr = (La - 1.000)% relative compaction
Cube Compressive All strength concrete Lr = 0.85 La
strength (excluding pavement concrete)
Bituminous binder Asphalt Lr = (La - 0.200)% binder
content % L'r = (L'a + 0.200)% binder
Cementitious-binder Chemically stabilised layers Lr = 0.80 La
content
Strength Chemically stabilised layers Lr = 0.85 La
(d) Determining the payment reduction factor (fr)

Where a lot is conditionally accepted, compensation will be reduced by multiplying the tender rates for
the Items concerned, as set out below, with the payment reduction factor f r
The factor fr is determined as follows in regard to the two cases set out in sub-clause 10307(c) above.
(ix) Case 1
The lot complies with the requirements for sample mean but not in all cases with the requirements for
single values.
fr is always taken as being equal to 0.85.
(x) Case 2
The lot complies with the requirements for single values, but not with the requirements for sample
mean ( ).
x n
For conditional acceptance at a lower limit
fr = 0.67 + 0.3( - Lr)/( La - Lr)

x n
For conditional acceptance at an upper limit
fr = 0.67 + 0.3 (L'r - ) / (L'r - L'a)

x n
(See Clause 10303 for definitions of symbols).
Where a lot is conditionally accepted with regard to bituminous binder application rates, the
appropriate payment reduction factor in table 10307/3 shall be applicable.

Table 10307/3: Payment Reduction Factors for Conditionally Accepted Bituminous Binder
Application Rates
Conventional and homogeneous modified Bitumen-rubber binders

binders
Deviation from the Payment Deviation from the Payment
specified rate reduction factor specified rate at reduction factor
(net cold bitumen) spraying temperature
2
l/m fr (%) fr
+/- 0.06 1.00 +/- 5.0 1.00
+/- 0.07 0.95 +/- 6.0 0.97
+/- 0.08 0.90 +/- 7.0 0.95
+/- 0.09 0.85 +/- 8.0 0.90
+/- 0.10 0.80 +/- 9.0 0.95
+/- 10.0 0.80
2
If the deviation exceeds ± 0.10 l/m , the lot shall If the deviation exceeds ± 10%, the lot shall be
be rejected. rejected.
(e) Applying the payment reduction factor

The payment-reduction factor shall be applied to the following payment items as described in the
specifications.
 Chemically stabilised layers: Items 42.01, 42.02, 46.01, 46.02, 46.05, 46.06, 46.07, 46.08
and 46.09.
 Asphalt surfacing and base: Items 64.01, 64.02, 64.03, 64.09, 64.10, 64.11, 64.12, 64.13
and 64.16.
 Surface treatments and seals (bituminous binder application rates): Item 63.07.
 Concrete: Items 84.01, 84.02 and 84.03. No reduction shall apply to payment items for
formwork, reinforcing or pre-stressing tendons.
 Plant-mixed pavement layers placed by paver: Items 71.02, 71.03, 71.12, 71.13, 71.14 and
71.15.
Where payment items are incorporated in the Particular Specifications or have been amended in the
Bills of Quantities, the payment-reduction factor shall apply to the payment items corresponding to the
payment items mentioned above.
Where a lot is conditionally accepted in regard to more than one property, the payment-reduction
factor for each property shall be calculated, and the factor giving rise to the largest reduction shall be
applied, except in the case of concrete pavements when the provisions of Clause 7120(f) shall apply.
10308 Process Control by the Contractor

The onus rests with the Contractor to produce work which conforms in quality and accuracy of detail to
all the requirements of the specifications and Drawings, and the Contractor shall, at his own expense,
institute a quality control system and provide experienced Engineers, foremen, surveyors, materials
technicians, other technicians and other technical staff, together with all transport, instrumentation and
equipment, to ensure adequate supervision and positive control of the works at all times.
The Contractor shall conduct tests or have them conducted continually on a regular basis, to check
the properties of natural materials and processed natural materials and of products manufactured on
the site, such as concrete and asphalt mixes. Although not a requirement for the Contractor to conduct
regular tests on any commercially produced products such a. cement, bitumen, steel and pipes, the
Contractor shall remain fully responsible for any defective material or equipment provided by him.

Similarly, the quality of all elements of the works shall be checked on a regular basis so as to ensure
compliance with the requirements of the specifications.
The intensity of control and of tests to be conducted by the Contractor shall be adequate to ensure
that proper control is being exercised.
Where any natural materials or products made from natural materials are supplied, and upon
completion of each element of the construction work, the Contractor shall test and check such
materials, products and/or elements for compliance with the specified requirements and shall submit
his results to the Engineer for approval. Such submission shall include all his measurements and test
results and shall furnish adequate proof of compliance with the specified requirements.
No specific Pay Items are provided as compensation for the above obligations, including the provision
of all samples delivered to the Engineer, the repair of places from which samples were taken, and the
provision of the necessary personnel and testing apparatus and facilities, for which compensation
shall be included in the tendered rates of the Contractor for the various items of work to which these
obligations apply.
For continuous concrete and asphalt-production processes, the Engineer may order the Contractor to
augment the above control system by introducing a process control system for monitoring the various
properties to be controlled. The specific system to be applied shall be subject to the Engineer's
approval, and the attention of the Contractor is drawn to the Systems described In Clause 4.4 of
TRH 5.
The Contractor shall take immediate steps to rectify any deviation from the specified requirements
indicated by his process-control system, and the Engineer shall have the right to inspect and be given
all details of tests and testing procedures in order to satisfy himself that the Contractor is implementing
adequate process control system.
10309 Quality of Materials and Workmanship

The Engineer will at regular intervals inspect and test materials and completed work for compliance
with the specified requirements, and, where applicable, the various specified judgement plans will be
applied. The testing frequencies and sample and lot sizes for routine testing shall be at the discretion
of the Engineer.
All sections of completed work shall be submitted to the Engineer for routine inspection and testing,
and the Contractor shall not cover up or construct any work on top of sections of completed work
before being advised by the Engineer of the outcome of the inspection or testing. The Contractor shall
arrange for the submission of work for testing in such a manner as will afford the Engineer reasonable
opportunity for inspection and testing.

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THE FEDERAL DEMOCRATIC REPUBLIC OF

ETHIOPIAN ROADS AUTHORITY

Standard Technical Specifications

and Method of Measurement

Addis Ababa, 2013

Ethiopian Roads Authority Page i

1. Geometric Design Manual

 Series – eg Series 1000: General

Page ii Ethiopian Roads Authority

1. Users of the specifications must register on the ERA website: www.era.gov.et

Ethiopian Roads Authority Page iii

ETHIOPIAN ROADS AUTHORITY

Manual Change Action

Authority Date Signature Recommended Action Approval

Director Quality Assurance

Deputy Director General Eng.Ops

Approval / Provisional Approval / Rejection of Change:

Page iv Ethiopian Roads Authority

Executive Review Group

No. Name Organization

1 Dr. Alemgena Araya Ethiopian Roads Authority

2 Ato Bekele Jebessa Ethio Infra Engineering plc

Ethiopian Roads Authority Page v

List of Persons Contributing to Peer Group Review

No. Name Organization

2 Ato Ahmed Mohammed Associated Engineering Consultants

3 Ato Alemayehu Ayele Ethiopian Roads Authority

4 Ato Amare Assefa Ethiopian Roads Authority

5 Ato Begashaw Debele Net Consult

6 Ato Bekele Jebessa Ethio Infra Engineering plc

7 Ato Bizuneh Kebebe Civil Works Consulting Engineers

8 Ato Brook Shamsu Labour Base Association

9 Ato Daniel Nebro DNH Consult

10 Ato Dereje Gezahegn Classic Consulting Engineers

11 Ato Efrem Gebre Egziabher Core Consulting Engineers

12 Ato Ezra Mersha Associated Engineering Consultants

13 Ato Frew Bekele Ethiopian Roads Authority

14 Ato Frew Terefe Ethiopian Roads Authority

15 Ato Kefargachew Kassahun Ethiopian Roads Authority

Construction Contractors Association of

17 Ato Melka Bekele Ethiopian Roads Authority

18 Ato Mulugeta Demissie Ethiopian Roads Authority

19 Ato Muse Belew Ethiopian Roads Authority

20 Ato Nigatu Widneh Ethiopian Roads Authority

21 Ato Shimeles Tesfaye SPICE Consult

22 Ato Shimelis Tilahun Net Consulting Engineers and Architects

23 Ato Sileshi Degefa Ethiopian Roads Authority

24 Ato Solomon Kulich Scott Wilson

25 Ato Teshome Worku CORE Consulting Engineers

26 Ato Yoseph Kidane Private

27 Dr. Alemgena Araya Ethiopian Roads Authority

28 Mr. Dick L-J WSP

29 W/ro Hiwot Mosisa Ethiopian Roads Authority

Page 0000-vi Ethiopian Roads Authority

No. Name Organisation Role

AFCAP Coordinator for

2 Abdo Mohammed ERA Project Coordinator

3 Frew Bekele ERA Project Coordinator

4 Rob Geddes AFCAP/Crown Agents Technical Manager

5 Les Sampson AFCAP/Crown Agents Project Director/Lead Author

6 Brian Barr AFCAP/Crown Agents Specialist Contributor

7 John Rolt AFCAP/Crown Agents Specialist Contributor

8 Gareth Hearn AFCAP/Crown Agents Specialist Contributor

9 Manaye Ewunetu AFCAP/Crown Agents Specialist Contributor