Professional Documents
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Table of Content
TABLE OF CONTENT
5101 Scope..................................................................................................................................7
5102 Materials.............................................................................................................................7
5103 Material Sources for Sub-Bases.........................................................................................7
5104 Material Requirements For Gravel Sub-Base ..................................................................7
(a) General......................................................................................................................7
(b) Grading Limits..........................................................................................................7
(c) Grading Modulus......................................................................................................8
(d) Plasticity Index .........................................................................................................8
(e) Californian Bearing Ratio (CBR) .............................................................................8
(f) Compaction requirements.........................................................................................8
(g) Los Angeles Abrasion ..............................................................................................9
5105 Material Requirements For Crushed Stone Sub-Base........................................................9
(a) General......................................................................................................................9
(b) Grading Limits..........................................................................................................9
(c) Grading Modulus....................................................................................................10
(d) Plasticity Index (PI) ................................................................................................10
(e) Compaction Requirements .....................................................................................10
(f) Los Angeles Abrasion ............................................................................................10
(g) Particle shape; Flakiness Index ..............................................................................10
5106 Construction Requirements For Sub-Bases Using Recycled Material ............................10
(a) General....................................................................................................................10
(b) Milling/Scarifying ..................................................................................................10
(c) Placing, Spreading and Compacting.......................................................................11
5107 Construction Requirements..............................................................................................11
(a) General....................................................................................................................11
(b) Stabilization............................................................................................................11
(c) Trial Areas ..............................................................................................................11
(d) Traffic on Sub-base ................................................................................................11
5108 Protection and Maintenance.............................................................................................12
5109 Sub-Base as a Filter or Separating Layer.........................................................................12
5110 Classification of Layers for Payment Purposes ...............................................................12
5111 Construction Tolerances ..................................................................................................12
(a) Levels .....................................................................................................................12
(b) Width ......................................................................................................................13
(c) Thickness ................................................................................................................13
5301 Scope................................................................................................................................42
5302 Selecting The Material .....................................................................................................42
Item 54.11 Extra over Pay item 54.08 for compacting pavement excavation floor in
restricted areas ........................................................................................................59
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 subbase is being placed.
(a) General
Gravel material to be used for sub-base shall be obtained from approved sources in borrow
areas, cuts or existing pavement layers. The complete sub-base shall contain no material
having a maximum dimension exceeding two-thirds of the completed layer thickness.
Gravel Sub-base material shall, unless otherwise stated, conform to the following
requirements.
The complete sub-base shall contain no material having a maximum dimension exceeding
two-thirds of the compacted layer thickness.
Sub-base material shall, unless otherwise authorized, conform to the following requirements
when finally placed:
(a) General
The aggregate used for crushed stone sub-base shall be derived from a parent rock that is
hard, sound, durable, and unweathered. It shall be obtained from sound rock from an
approved quarry or clean sound boulders. It shall contain no deleterious material such as
decomposed rock, clay, shale, or mica. The crushed aggregate shall comply with the following
requirements:
Tests to determine whether the crushed stone material complies with the specified grading
requirements shall be conducted after the material has been mixed on the road and spread out.
The aggregate shall be produced entirely by the crushing of rock or boulders. Single stage
crushing will not be allowed and the crusher installation shall be capable of producing
material complying with the specified requirements. If, however, 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.
(a) General
Construction of sub-bases using recycled (in-situ) existing pavement materials shall comply
with the requirements of Clause 5105 and with the requirements of this Clause.
(b) Milling/Scarifying
(i) Before scarification or milling is commenced, 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 described in the Contract
either by scarifying or by the use of an approved milling machine.
(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 200mm and not less than 100mm. The final compacted layer shall be free from
concentrations of coarse or fine materials.
1. The surface of each completed layer shall be moistened prior to the construction of
the succeeding layer. Determine the optimum moisture content according to AASHTO T 180
method D. Mix the aggregate and adjust the moisture content to obtain a uniform mixture
with moisture content within 2 percent of the optimum moisture content. Spread and shape
the mixture on the prepared surface in a uniform layer.
2. The material shall be compacted by the use of approved rollers progressing gradually
from the outside 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. Compact each layer full
width. Roll from the sides to the center, parallel to the centerline of the road. Along curbs,
headers, walls, and all places not accessible to the roller, compact the material with approved
tampers or compactors. 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. Compact each layer to at least
95 percent of maximum density. Determine the in place density and moisture content
according to AASHTO T 238 and AASHTO T 239 or other approved test procedures.
(b) Stabilization
When specified in the contract or required by the engineer, sub-base layers shall be stabilized
as specified in Division 4600.
(a) Levels
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 + 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 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.
5112 TESTING
Testing Frequency
Test One test Minimum number of tests per lot
every
Materials
Field density and OMC 2 510 m2 4
The density requirements specified in Clause 5105 for compaction of subbase shall be deemed
to have been complied with if the minimum dry densities as shown in Table 5112/2 are
equaled or exceeded.
In calculating the mean, density values differing by more than 5 percentage points from the
mean shall be disregarded and a new mean calculated.
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 so that after
being repaired it will comply with the specified requirements.
Note: 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.
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, crushing or soft excavation
or pits, breaking down, placing and compacting the material, including transporting the
material for a distance of 1.0 km and its removal, disposal and transporting for a distance of
1.0 km, of up to 5% by volume of oversize material, and the protection and maintenance of
the layer and the conducting of control tests, all as specified.
Item 51.02 Extra over Pay item 51.01 for excavation of material in:
(a) Intermediate excavation ..................................................................... cubic metre (m3)
(b) Hard excavation................................................................................... cubic metre (m3)
The unit of measurement shall be the cubic metre of material obtained from intermediate or
hard excavation.
The tendered rates shall include full compensation for the additional costs involved for taking
material from classes of material harder than soft excavation and for the additional costs, if
any, for processing such material in the pavement layers.
Item 51.03 Sub-base layer constructed from gravel or crushed stone obtained from
existing pavement layers:
(a) Gravel sub-base (unstabilized gravel) compacted to 95% of modified AASHTO
density, using:
(i) Non-cemented material (specify compacted layer thickness) ... cubic metre (m3)
(ii) Cemented material (specify compacted layer thickness)........... cubic metre (m3)
(ii) Cemented material (specify compacted layer thickness) ...........cubic metre (m3)
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 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, placing and
compacting the material, including haul for a free-haul distance of 1.0 km, and for the
protection and maintenance of the layer as well as 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 cemented material shall include full compensation of breaking down the
material to comply with the specified grading requirements.
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, 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 it be 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
51.07.
The tendered rate for cemented material shall include full compensation for breaking down
the material to comply with the specified grading requirements.
Item 51.05 Sub-base layer constructed Extra over Pay item 51.03 (a),(b),(c)&(d) and
Pay item 51.04 (a),(b)&(c) from recovered pavement material mixed with
existing bituminous surfacing material
The unit of measurement shall be in cubic metre (m3).
The tendered extra-over rate for constructing the pavement layers from material recovered
from existing pavements and mixed with existing bituminous surfacing material shall include
full compensation for breaking down the surfacing material into fragments not exceeding 37.5
mm in size, uniformly mixing it with the other material, manually removing any over-sized
fragments, and for any other incidentals.
Item 51.06 Extra over Pay item 51.04 for adding extra material as specified below:
(a) Gravel sub-base ................................................................................... cubic metre (m3)
(b) Crushed stone Sub-base....................................................................... cubic metre (m3)
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 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, 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 and adding the material to the
in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km.
Item 51.07 Extra over Pay item 51.04 for temporarily blading the material to windrow
The unit of measurement shall be a cubic metre (m3) 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 and later 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 51.08 Extra over Pay item 51.03 for excavating material in existing pavement
layers in restricted areas:
(a) Non-cemented material........................................................................cubic metre (m3)
(b) Cemented material ...............................................................................cubic metre (m3)
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 the
material in restricted areas.
Item 51.09 Compacting the floors of pavement excavations (5 roller passes) with:
(a) Vibratory rollers ................................................................................. square metre (m2)
(b) Oscillatory rollers .............................................................................. square metre (m2)
(c) Grid rollers ......................................................................................... square metre (m2)
(d) Flat-wheeled rollers ........................................................................... square metre (m2)
(e) Pneumatic-tyred rollers...................................................................... square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted
by 5 roller passes. Payment will differentiate between the above types of rollers.
The tendered rate shall include full compensation for supplying the roller, applying 5 roller
passes, and removing the roller after completion of the compacting process. The engineer may
increase or decrease the number of roller passes, in which case payment will be adjusted in
accordance with pay item 51.11.
Item 51.11 Variations in the number of roller passes applicable to pay item 51.09:
(a) Vibratory rollers ............................................................. square metre- pass (m2 -pass)
(b) Oscillatory rollers ............................................................ square metre- pass (m2 -pass)
(c) Grid rollers ...................................................................... square metre- pass (m2 -pass)
(d) Flat-wheeled rollers......................................................... square metre- pass (m2 -pass)
(e) Pneumatic-tyred rollers ................................................... square metre- pass (m2 -pass)
Item 51.12 Extra over Pay item 51.09 for compacting pavement excavation floor in
restricted areas
The unit of measurement shall be a square metre (m2) of pavement excavation floor
compacted 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.
5201 SCOPE
This Division covers the specifications of materials for, and the construction of road base
pavement layers from approved base materials. It includes the use of crushed, screened or
crushed and screened stones or gravels, natural gravels, and stabilized base materials.
5202 DIMENSIONS
The road base layer shall be constructed to the dimensions and cross sectional profiles shown
in the Contract.
5203 MATERIALS
(a) General
Graded crushed stone (GB1):
This material is produced by crushing fresh, quarried rock (GB1) and may be an all-in
product, usually termed a 'crusher-run', or alternatively the material may be separated by
screening and recombined 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.
(b) Grading
The combined grading of the material shall be a smooth continuous curve falling within the
grading limits shown in Table 5200/1 when determined in accordance with the requirements
of AASHTO T-27. The mass of material passing the 0.075mm sieve shall be determined in
accordance with the requirements of AASHTO T-11.
Table 5200/1: Grading Limits for Graded Crushed Stone Base Course Materials (GB1)
Test sieve (mm) Percentage by mass of total aggregate passing test sieve
Nominal maximum particle size
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
0.075(1) 5 – 12 5 - 12 5 – 12
Note 1. For paver-laid materials a lower fine content may be accepted.
(a) General
Graded Natural Gravel (GB2, GB3):
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 base course materials. The material shall be of such a nature
that it can be readily transported, spread and compacted without segregation.
(b) Grading
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 5203/3 when determined in accordance with the requirements of AASHTO T-27. The
mass of material passing the 0.075mm sieve shall be determined in accordance with the
requirements of AASHTO T-11. Table 5200/3 contains two recommended particle size
distributions for suitable materials corresponding to maximum nominal sizes of 37.5 mm and
20 mm.
Test sieve (mm) Percentage by mass of total aggregate passing test sieve
Nominal maximum particle size
37.5 mm 20 mm
50 100 -
37.5 80 – 100 100
20 60 – 80 80 – 100
10 45 – 65 55 – 80
5 30 – 50 40 – 60
2.36 20 – 40 30 – 50
0.425 10 – 25 12 – 27
0.075 5 – 15 5 – 15
(f) Abrasion
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 Project Specifications.
(ii) Soundness
The loss of soundness of the coarse aggregate shall not be greater than 12% when tested in
accordance with AASHTO T-104.
(c) Filler
Where necessary to improve the combined grading or other properties of the mix, a filler of
either hydrated lime, cement or crushed rock or crushed boulder dust may be added. Filler
shall be material passing the 0.075mm sieve. If used as an anti-stripping agent, the quantity of
hydrated lime shall be at least 1.5% by weight of total aggregates and in no case shall the
quantity exceed 3% by weight of total aggregates.
(d) Binder
The binder shall be 60/70 penetration grade bitumen complying with the requirements of
AASHTO M-20.
Table 5200/4 Combined Aggregate Grading Limits for Dense Bitumen Macadam
Flow mm 2-4
Air Voids % 4.0 - 8.0
Voids in Mineral Aggregate % 16.0 - 22.0
Voids Filled with Bitumen % 65.0 - 85.0
Filler/Bitumen Ratio* % 1.0 - 1.6
Compaction Level Number of blows 2x50, 2x75 - To refusal
(Depending on Design
traffic)
Note :
1. For aggregate with fine microtexture e.g. limestone, the bitumen content should be reduced
by 0.1 to 0.3%.
2. 60/70 grade bitumen is preferred.
The mix proportions for each type of mixture to be used in the Works shall be determined
initially in accordance with the requirements of the Asphalt Institute Mix Design Manual
(MS2) using at least five binder contents. The Marshall specimens shall be compacted using
75 blows on each face. Trial mixes shall be carried out using various combined aggregate
gradings within the limits stipulated within Table 5200/4 in order to determine the optimum
design within the stipulated parameters in Table 5200/5 for the materials being used.
Prior to final approval of the proposed job mix formula, mixes shall be compacted to refusal
using the extended Marshall compaction method (in accordance with the requirements of BS
598 Part 104 (1989)) and the resulting air voids in the mix shall not be less than 3%.
(a) Equipment
The material shall be laid either by a self-propelled paving machine or by means of a grader,
as described in the Contract. It shall be so designed and operated as to produce a mixture of
laid material complying with the requirements of 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.
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 rock or crushed boulder road 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 a combination of these.
Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient
means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with
a quick and smooth acting reversing mechanism.
The mixed material shall be transported at the required moisture content and in such a way,
that no segregation occurs.
Unless otherwise described in the Contract, the material shall be laid by a self-propelled
paving machine approved by the Engineer. 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.
The material shall be spread in layers not exceeding 200mm and not less than 100mm
compacted thickness.
The material shall be compacted by the use of approved rollers progressing gradually from the
outside 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 T-180 method D.
The in-situ density of the completed layer shall be determined in accordance with the
requirements of AASHTO T-191.
Alternatively, if approved by the Engineer, the dry density may be determined by use of a
nuclear densometer in direct transmission mode in accordance with AASHTO T238-86
Method B or ASTM D 2992-96. The nuclear densometer shall be accurately calibrated before
use, and at interval thereafter, and correlated against results obtained in accordance with
AASHTO T-191.
(c) Stabilization
When specified in the contract or required by the engineer, base layers shall be stabilized as
specified in Division 4600.
(a) Equipment
The material shall be laid either by a self-propelled paving machine or by means of a grader,
as described in the Contract. It shall be so designed and operated 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.
Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient
means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with
a quick and smooth acting reversing mechanism.
The in-situ density of the completed layer shall be determined in accordance with the
requirements of AASHTO T-191.
Alternatively, if approved by the Engineer, the dry density may be determined by use of a
nuclear densometer in direct transmission mode in accordance with AASHTO T238-86
Method B or ASTM D 2992-96. The nuclear densometer shall be accurately calibrated before
use, and at interval thereafter, and correlated against results obtained in accordance with
AASHTO T-191.
(c) Stabilization
When specified in the contract or required by the engineer, base layers shall be stabilized as
specified in Division 4600.
(a) Equipment
All equipment used for the mixing and paving of the Dense Bitumen Macadam Road Base
material shall be so designed and operated 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.
The mixing plant shall be either a batch or a continuous type complying with the requirements
of AASHTO 156 and approved by the Engineer. It shall be equipped with satisfactory means
of accurately controlling the mix proportions of all constituent materials.
The crushing and screening plant shall be capable of crushing and screening the aggregates, to
be used for Dense Bitumen Macadam Road Base material, into at least four different sized
fractions.
Vehicle used for transporting the mixed material shall have tipping bodies capable of
discharging directly into the paving machine. The bodies of the vehicles shall be capable of
containing the mixed material without spillage.
All vehicles shall be equipped with a canvas or other approved type of cover which shall be
used to cover the mixed material upon loading at the mixing plant and shall not be removed
until the mixed material is discharged into the paving machine.
Dense Bitumen Macadam Road Base material shall be laid by an approved type of self-
propelled spreading/finishing machine capable of laying to the required widths, thicknesses
and cross sectional profiles shown in the Contract without causing segregation, dragging or
other surface defects.
All paving machines shall be fitted with automatic electronic screed control. Paving machines
shall be equipped with heated screeds and with 60o or 45o angle, confining side plates. Paving
machines shall also be equipped with an infra-red joint heating system.
Compaction shall be carried out using self-propelled 8 – 10 tonnes deadweight smooth, steel
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.
Rollers shall be equipped with adjustable scrapers for cleaning the drums and an efficient
means of moistening the drums to prevent adhesion of asphalt. The rollers shall be fitted with
a quick and smooth acting reversing mechanism.
All transverse and longitudinal construction joints shall be made vertical and offset at least
300mm from joints in the underlying layer. Prior to the spreading of the adjacent layer the
cold edge of the joint shall be reheated to at least the minimum rolling temperature and
primed with cut-back bitumen to the approval of the Engineer.
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.
The material shall be spread in layers not exceeding 125mm and not less than 55mm
compacted thickness.
Compaction shall be carried out using rollers stipulated in Clause 5210(a) above.
Vibrating rollers, if used, shall be set in a non-vibrating mode. Rolling shall progress
gradually from the outside 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.
The temperature of the spread material at the time compaction commences shall not be less
than 135o C. The compaction shall be completed before the temperature of the laid material
falls below 105o C.
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 density of the compacted layer shall be related to the daily Marshall Density, which shall
be determined by making four standard Marshall specimens from samples of the mix taken
from the mixing plant and the paving machine. The density of each sample shall be
determined and compared with the mean value. Any individual result, which varies from the
mean by more than 0.015, shall be rejected. Marshall tests shall be repeated on a daily basis to
establish the daily Marshall Density for each day’s production.
The daily Marshall Density shall not vary from the job mix design density by more than ±2%.
The density achieved in the completed layer shall be shall not less than 97% of the Marshall
Density for each day’s production.
2 0.34
5 0.27
10 0.21
20 0.13
30 0.08
(b) 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.
(c) 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 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.
The unit of measurement shall be the cubic metre of completed gravel base or crushed-stone
base in place as the case may be, 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, breaking down, placing and compacting the material, including transporting the material
for a distance of 1.0 km and its removal, disposal and transporting for a distance of 1.0 km, of
up to 5% by volume of oversize material, and the protection and maintenance of the layer and
the conducting of control tests, all as specified.
The tendered rates shall include full compensation for procuring, furnishing and placing all
materials, including the crusher fines or sand (if approved) necessary for correcting the
grading of the crushed stone, for crushing and screening, for hauling the material over an
unlimited free-haul distance where material is obtained from commercial sources, and over a
1.0 km free-haul distance where material is obtained from approved borrow pits, for rolling,
slushing and correcting the layers, and for testing, protecting and maintaining the work as
specified.
Macadam base course , completed and accepted , will be measured in square metre or in tons
as called for in the proposal. The tendered rates shall include full compensation for procuring,
furnishing, hauling, mixing, placing and compacting all materials, priming as specified and
for all labour, equipment, tools, maintenance and incidentals necessary to complete the work
described in this division.
Item 52.02 Extra over Pay Item 52.1 for excavation of material
(a) Intermediate excavation. ..................................................................... cubic metre (m3)
(b) Hard excavation................................................................................... cubic metre (m3)
The unit of measurement shall be the cubic metre of material obtained from intermediate or
hard excavation.
The tendered rates shall include full compensation for the additional costs involved for taking
material from classes of material harder than soft excavation and for the additional costs, if
any, for processing such material in the pavement layers.
Item 52.03 Base layer constructed from material obtained from existing pavement
layers:
1. Gravel base material:
(a) Gravel base (unstabilized gravel) compacted to 98% of modified AASHTO density,
using:
(i) Non-cemented material
(Specify compacted layer thickness) ......................................... cubic metre (m3)
(ii) Cemented material
(Specify compacted layer thickness) ......................................... cubic metre (m3)
(b) Gravel base (unstabilized gravel) compacted to 100% of modified AASHTO density
using:
(i) Non-cemented material
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.
The tendered rate shall include full compensation for breaking up the existing pavement layer,
excavating the material in the existing pavement, procuring, breaking down, placing and
compacting the material, including haul for a free-haul distance of 1.0 km, and for the
protection and maintenance of the layer as well as 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 cemented material shall include full compensation of breaking down the
material to comply with the specified grading requirements.
The tendered rates for milled-out material shall also include full compensation for loading the
material at the stockpile and for hauling it to a screening plant where applicable or to the point
of use for a free-haul distance of 1.0 km, and for any additional processing required to bring
the material up to the required standards, but shall not include compensation for milling.
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.
(b) Gravel base (unstabilized gravel chemically stabilized material) compacted to 100%
of modified AASHTO density using:
(i) Non-cemented material
(specify compacted layer thickness) .......................................... cubic metre (m3)
(ii) Cemented material
(specify compacted layer thickness) .......................................... cubic metre (m3)
The unit of measurement shall be as shown for the three cases, 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, 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 it be 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
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:
(a) Gravel base ........................................................................................ cubic metre (m3)
(b) Crusher fines for improving the grading of recovered crushed stone
(i) Material from approved borrow pits ......................................... cubic metre (m3)
(ii) Material from commercial sources ............................................ cubic metre (m3)
(c) Macadam base materials added.............................................. square meter (m2) or ton
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 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 and adding the material to the
in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km.
Item 52.06 Extra over Pay item 52.04 for temporarily blading the material to windrow
....................................................................................................Cubic metre (m3)
The unit of measurement shall be a cubic metre of material from an existing pavement layer,
temporarily bladed to windrow and measured in its original position before removal.
The tendered rate shall include full compensation for all additional costs involved in
temporarily 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.
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 52.07 Extra over Pay item 52.03 for excavating material in existing pavement
layers in restricted areas:
(a) Non-cemented material ...................................................................... cubic metre (m3)
(b) Cemented material............................................................................... cubic metre (m3)
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 the
material in restricted areas.
Item 52.08 Compacting the floors of pavement excavations (5 roller passes) with:
(a) Vibratory rollers area ........................................................................ square metre (m2)
(b) Oscillatory rollers area ..................................................................... square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted
by 5 roller passes. Payment will differentiate between the above types of rollers.
The tendered rate shall include full compensation for supplying the roller, applying 5 roller
passes, and removing the roller after completion of the compacting process. The engineer may
increase or decrease the number of roller passes, in which case payment will be adjusted in
accordance with pay item 52.10.
Item 52.09 Watering the pavement excavation floor ........................................ kilolitre (kl)
The unit of measurement shall be kilolitre of water applied to the floor of the excavation to be
compacted on the instruction of the engineer.
The tendered rate shall include full compensation for procuring and applying the water,
including all hauls.
Item 52.10 Variations in the number of roller passes applicable to pay item 52.08:
(a) Vibratory rollers area ........................................................................ square metre (m2)
(b) Oscillatory rollers area...................................................................... square metre (m2)
(c) Grid rollers area ................................................................................ square metre (m2)
(d) Flat-wheeled rollers area ................................................................... square metre (m2)
(e) Pneumatic-tyred rollers area ............................................................. square metre (m2)
Item 52.11 Extra over Pay item 52.08 for compacting pavement excavation floor in
restricted areas .......................................................................square metre (m2)
The unit of measurement shall be a square metre of pavement excavation floor compacted 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.
Only trial sections in which the base material and the completed layer comply with all the
requirements of the specifications shall be paid for.
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.
(a) General
1) 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 the fact that work may have to be carried
out in restricted areas.
2) No additional pavement will be made for restricted areas.
3) Only approved cutting or sawing equipment may be used for cutting or sawing the
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.
5305 CONSTRUCTION
(a) General
Where all or a 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 project specifications or ordered by the Engineer, the existing
bituminous material shall first be removed before the underlying layers are broken up.
Bituminous material may 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, all at his own cost.
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 by the contractor at his own 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, expect 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 project specifications,
irrespective of the type of material in the existing pavement layer.
Where pavement layers are broken down over a section of he 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.
(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.
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
therefor 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.
(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:
(i) Not exceeding 30 mm ................. .............................................square meter (m2)
(ii) Exceeding 30 mm but not exceeding 60 mm........................... square meter (m2)
(iii) Exceeding 60 mm ................ ....................................................square meter (m2)
The unit of measurement shall be a square meter 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:
(a) Not exceeding 30 mm............................ ..............................................cubic meter (m3)
(b) Exceeding 30 mm but not exceeding 60 mm ..................................... cubic meter (m3)
(c) Exceeding 60 mm............................. ...................................................cubic meter (m3)
The unit of measurement shall be a cubic meter of asphalt milled out and removed to
approved stockpiles.
The tendered rate shall include full compensation for providing milling equipment and milling
out the material to the specified depth and in accordance with the requirements for evenness
and for all measurements, labor, 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 irrespective of the method of loading, and for unloading the material and
placing it in stockpile, also 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:
(a) Non-cemented material........................................................................cubic meter (m3)
(b) Cemented material ...............................................................................cubic meter (m3)
The unit of measurement shall be a cubic meter 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.
The unit of measurement for subitems (a) and (c) shall be the square meter of sawcut area
calculated in accordance with the authorized length of sawcut and the average saw depth
measured after excavation of the material. The unit of measurement for subitem (b) shall be
the meter of cut measured in accordance with the authorized 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 30 mm thickness is sawn together
with a cemented pavement, the surfacing section shall be deemed to be cemented material for
payment purposes.
Item 53.05 Removing the remaining asphalt from the underlying layer
The unit of measurement shall be the square meter of excavation floor cleaned on the
instruction of the Engineer.
The quantity will be calculated in accordance with the authorized 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 instructed by the Engineer.
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.
5401 SCOPE
This Division covers the specification of materials for, and the construction of, gravel wearing
course and gravel shoulders from crushed rock, crushed boulders, crushed gravel or as-ripped
weathered rock.
The gravel wearing course and gravel shoulders shall be constructed to the dimensions and
cross sectional profiles shown in the Contract drawings.
(a) General
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.
They should have sufficient cohesion to prevent ravelling and corrugating (especially in dry
conditions).
The amount of fines (particularly plastic fines) should be limited to avoid a slippery surface
under wet conditions.
Selected material shall consist of hard durable angular particles of fragments of stone or
gravel. The material shall be free from vegetable matter and lumps or balls of clay.
(b) Grading
The grading of the gravel after placing and compaction shall be a smooth continuous curve
within and approximately parallel to the envelopes or the grading limits shown in Table
5403/1 when determined in accordance with the requirements of AASHTO T-27.
The mass of material passing the 0.075mm sieve shall be determined in accordance with the
requirements of AASHTO T-11.
Table 5403/1 Grading Requirements for Gravel Wearing Course and Gravel Shoulder
Test Sieve Percent (%) by mass of total aggregate passing test sieve
Size(mm)
Type 1 Type 2 Type 3 Type 4 Type 5 Type 6
- - - 100 - -
50
100 - 100 80-100 - -
37.5
- 100 95 - 100 - - -
28
80 - 100 95 - 100 85-100 60-80 100 -
20
- 80-100 65 - 100 - - -
14
55 - 100 65 - 100 55 - 100 45-65 80 - 100 100
10
40 - 60 45 - 85 35-90 30-50 60 -85 80-100
5
30 - 50 - - 20-40 45-70 50-80
2.36
- 30 - 65 22-75 - - -
2
- 25-55 18-60 - - -
1
15 - 30 18 - 45 15-50 10-25 25-45 25-45
0.425
5 - 15 12-32 10-40 5-15 10-25 10-25
0.075
(i) Type 1
The grading of this gravel after placing and compaction shall be a smooth curve within and
approximately parallel to the envelopes detailed in Table 5403/1.
The material shall have a percentage of wear of not more than 50 at 500 revolutions, as
determined by AASHTO T96.
The material shall be compacted to a minimum in-situ density of 95% of the maximum dry
density determined in accordance with the requirements of AASHTO T 180.
The plasticity index should be not greater than 15 and not less than 8 for wet climatic zones
and should be not greater than 20 and not less than 10 for dry climatic zones.
The linear Shrinkage should be in a range of 3-10%.
Note that the above gradation and plasticity requirements are only to be used with angular
particles and that crushing and screening are likely to be required in many instances for this
purpose. The crushed ratio shall be a minimum of 60%.
(iii) Type 4
This material gradation allows for larger size material and corresponds to the gradation of a
base course material. The use of this gradation of materials is subject to the local experience
and shall be used with PIs in a range of 10-20.
(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.
(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.
The material shall be compacted by the use of approved rollers progressing gradually from the
outside 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 be 95% of the maximum dry density when
determined in accordance with the requirements of AASHTO T-180 method D. The dry
density shall be determined in accordance with the requirements of AASHTO T-190.
Alternatively, if approved by the Engineer, the dry density may be determined by use of a
nuclear densometer, which shall be accurately calibrated before use, and at intervals
thereafter, against results obtained in accordance with AASHTO T-190.
2 0.34
5 0.27
10 0.21
20 0.13
30 0.08
(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.
The minimum dry densities given in Table 5406/2 shall be equaled or exceeded.
Item 54.01 Gravel Wearing course and Shoulder constructed from gravel taken from
cut or borrow, including free-haul up to 1.0 km
(a) Gravel wearing course compacted to 95% of modified AASHTO density specify
compacted layer thickness)............................................................................... cubic metre (m3)
(b) Gravel shoulders wearing course compacted to 95% of modified AASHTO density
(specify compacted layer thickness).................................................................. cubic metre (m3)
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, as if from soft excavation or
pits, breaking down, placing and compacting the material, including transporting the material
for a distance of 1.0 km and its removal, disposal and transporting for a distance of 1.0 km, of
up to 5% by volume of oversize material, and the protection and maintenance of the layer and
the conducting of control tests, all as specified.
Item 54.02 Extra over Pay item 54.01 for excavation of material in
(a) Intermediate excavation ..................................................................... cubic metre (m3)
(b) Hard excavation .................................................................................. cubic metre (m3)
The unit of measurement shall be the cubic metre of material obtained from intermediate or
hard excavation.
The tendered rates shall include full compensation for the additional costs involved for taking
material from classes of material harder than soft excavation and for the additional costs, if
any, for processing such material in the pavement layers.
Item 54.03 Gravel Wearing course and Shoulder constructed from gravel obtained
from existing pavement layers:
(a) Gravel wearing course compacted to 95% of modified AASHTO density, using:
(i) Non-cemented material
(specify compacted layer thickness)...........................................cubic metre (m3)
(ii) Cemented material
(Specify compacted layer thickness)..........................................cubic metre (m3)
(b) Gravel shoulder wearing course compacted to 95% of modified AASHTO density,
using:
(i) Non-cemented material
(specify compacted layer thickness)...........................................cubic metre (m3)
(ii) Cemented material
(Specify compacted layer thickness)..........................................cubic metre (m3)
The unit of measurement shall be the cubic metre of compacted 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 54.01, 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, placing and
compacting the material, including haul for a free-haul distance of 1.0 km, and for the
protection and maintenance of the layer as well as 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 cemented material shall include full compensation of breaking down the
material to comply with the specified grading requirements.
Item 54.04 In situ reconstruction of existing gravel wearing course and shoulder layer
as
(a) Gravel wearing course compacted to 95% of modified AASHTO density, using:
(i) Non-cemented material
(specify compacted layer thickness) .......................................... cubic metre (m3)
(ii) Cemented material
(Specify compacted layer thickness) ......................................... cubic metre (m3)
(b) Gravel shoulder wearing course compacted to 93% of modified AASHTO density,
using:
(i) Non-cemented material
(specify compacted layer thickness) .......................................... cubic metre (m3)
(ii) Cemented material
(Specify compacted layer thickness) ......................................... cubic metre (m3)
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 layer to the
specified depth, breaking down and preparing the material, 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 it be 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
54.06.
The tendered rate for cemented material shall include full compensation for breaking down
the material to comply with the specified grading requirements.
Item 54.05 Extra over Pay item 54.04 for adding extra material as specified below:
(a) Gravel wearing course......................................................................... cubic metre (m3)
(b) Gravel shoulder wearing course .......................................................... cubic metre (m3)
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 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, 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 and adding the material to the
in situ broken- down pavement layer and for haul over a free-haul distance of 1.0 km.
Item 54.06 Extra over Pay item 54.04 for temporarily blading the material to windrow
The unit of measurement shall be a cubic metre (m3) 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 and later 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 54.07 Extra over Pay item 54.03 for excavating material in existing pavement
layers in restricted areas:
(a) Non-cemented material ...................................................................... cubic metre (m3)
(b) Cemented material ..............................................................................cubic metre (m3)
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 the
material in restricted areas.
Item 54.08 compacting the floors of pavement excavations (5 roller passes) with:
(a) Vibratory rollers ................................................................................. square metre (m2)
(b) Oscillatory rollers ............................................................................. square metre (m2)
(c) Grid rollers ....................................................................................... square metre (m2)
(d) Flat-wheeled rollers ......................................................................... square metre (m2)
(e) Pneumatic-tyred rollers .................................................................... square metre (m2)
The unit of measurement shall be a square metre of floor of pavement excavations compacted
by 5 roller passes. Payment will differentiate between the above types of rollers.
The tendered rate shall include full compensation for supplying the roller, applying 5 rollers
passes, and removing the roller after completion of the compacting process. The engineer may
increase or decrease the number of roller passes, in which case payment will be adjusted in
accordance with pay item 54.10.
Item 54.10 Variations in the number of roller passes applicable to pay item 54.08
(a) Vibratory rollers ................................................................................ square metre (m2)
(b) Oscillatory rollers .............................................................................. square metre (m2)
(c) Grid rollers ....................................................................................... square metre (m2)
(d) Flat-wheeled rollers........................................................................... square metre (m2)
(e) Pneumatic-tyred rollers ..................................................................... square metre (m2)
Item 54.11 Extra over Pay item 54.08 for compacting pavement excavation floor in
restricted areas
The unit of measurement shall be a square metre (m2) of pavement excavation floor
compacted 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.