QCS 2014 - Section 6 Road Works

QCS 2014 Section 06: Road Works Page 1
Part 01: General
1 GENERAL ............................................................................................................... 2
1.1 RELATED DOCUMENTS & REGULATIONS ................................................ 2
1.2 BENCH MARKS AND MONUMENTS............................................................ 2
1.2.1 General 2
1.2.2 Permanent Monuments 2
1.2.3 Setting Out 3
1.3 EXISTING GROUND LEVELS....................................................................... 3
1.4 MATERIALS TESTING .................................................................................. 4
1.5 NUCLEAR DENSITY TESTING DEVICES .................................................... 5
1.6 TEMPORARY FENCING ............................................................................... 5
1.7 ROAD OPENING ........................................................................................... 5
1.8 CONCRETE WORKS .................................................................................... 5
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1.9 STANDARDS AND CODES OF PRACTICE ................................................. 6
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1.10 TRAFFIC MANAGEMENT ............................................................................. 6
1.11 ARMED FORCES .......................................................................................... 6
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Part 01: General
1 GENERAL
1.1 RELATED DOCUMENTS & REGULATIONS
1 The information given in this Part is supplemental to QCS Section 1 - General. Reference
should be made to Section 1 – General prior to referring to the clauses in this part of the
specification which cover specific requirements for roadworks and are additional to Section 1
- General.
2 The Government specifications, regulations, notices and circulars mentioned in QCS Section
1 – General are amended and complemented by this Specification as detailed hereafter. In
the case of any ambiguity or discrepancy the provisions of this Specification shall prevail over
the provisions of the aforementioned Government published specifications.
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1.2 BENCH MARKS AND MONUMENTS
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1.2.1 General
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1 The Contractor shall consult the Survey Section of the Ministry of Municipal Affairs and
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Agriculture prior to any earthworks or site clearance to determine if the work is likely to
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disturb survey marks.
2 If the survey section require a survey mark to be moved the Contractor will be responsible for
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recreating the survey mark to an approved design and specification, and for re surveying the
point using survey companies approved by the Survey Section.
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3 On the Practical Completion of the Works the Survey Section will issue a certificate stating
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that all survey marks, whether disturbed or otherwise, by the Contractor have been reinstated
or protected to the satisfaction of the Survey Section.
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4 In the event of failure to comply with the requirements of this Clause the Government, without
prejudice to any other method of recovery, may deduct the costs of any remedial work after
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the Practical Completion date, carried out by Survey Section from any monies in its hands
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due to or which may become due to the Contractor.

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5 All pertinent levels, lines and locations must be checked and verified by the Contractor before
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commencing the Works.
1.2.2 Permanent Monuments
1 At the time of substantial completion of the whole of the works, a schedule and plan drawings
of all remaining Project related and supplementary bench marks and monuments shall be
prepared and transmitted to the Engineer. All project related bench marks and monuments
made permanent as above will be shown on the as-built plans, including the co-ordinates and
level information for each.
2 Certain bench marks and monuments determined by the Engineer shall be made into
permanent bench marks and monuments.
Part 01: General
3 Fabrication and installation of bench marks and monuments shall be as shown on the
drawings or in the specifications and shall include attaching warning reflectors and painting if
required. Each bench mark and monument shall be set accurately at the required location
and elevation and in such manner as to ensure its being held firmly in place.
4 The Contractor may request the Engineer's approval for concrete monuments, markers and
posts supplied by an established commercial manufacturer, whose capability of producing
survey monuments has been well established by both testing and performance. Written
approval shall be obtained prior to installation of the units on the project.
1.2.3 Setting Out
1 The level datum for the works shall be the Qatar Datum as defined by the PWA.
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2 The works shall be set out to the Qatar national grid as defined by the PWA. The Contractor
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will be supplied with the details and grid reference of setting out monuments.
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3 The works shall be set out in accordance with the standard specification of the PWA.
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4 Before commencing the works the Contractor shall obtain from the Engineer all information
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pertaining to project related bench marks and monuments bearing local grid co-ordinates.
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5 After the Contractor takes possession of the Contract Drawings and has noted all the existing
bench marks, he shall carry out at his own expense the setting out of the works, definition of
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levels, centre lines and slopes, all in accordance with the Drawings.
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6 The Contractor shall be responsible for the true and proper setting out of the work in relation
to original points, lines and levels of references given in the Drawings and for the accuracy of
the positions, levels, dimensions and alignment of all parts of the work, and for any delay or
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loss resulting from errors made in completing the setting out of the work.
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7 The Contractor shall protect, preserve and be responsible for all existing bench narks, pegs
and boundary marks and shall keep these in place or replace them when necessary either in
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their positions or in other approved positions.

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8 Setting out shall be approved by the Engineer before commencing the Works, but such
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approval shall in no way relieve the Contractor of his responsibility for the correct execution of
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the works.
1.3 EXISTING GROUND LEVELS
1 The Contractor will survey cross-sections of the site prior to the commencement of works in
any section.
2 The Contractor shall include in his critical path programme the date by which survey work
should be completed in each section of the site. No works may commence in any section
prior to the programme date without the written approval of the Engineer.
3 Sections will be prepared at such intervals as are necessary to give a representative record
of existing conditions and in no case will the intervals exceed 50 metres.
Part 01: General
4 The Engineer may choose to carry out his own survey of the site and in such cases will give
the Contractor 48 hours notice of his intention to carry out survey work in any particular
section of the Site.
5 The Contractor may nominate a representative to be present to observe the survey. If, having
been given such notice, the Contractor fails to appoint a representative or if the
representative should fail to be present during the survey work, the Engineer shall proceed
with the survey which shall be deemed to have been prepared in the presence of the
Contractor.
6 The Contractor shall prepare drawings showing the various cross-sections obtained from the
above survey.
7 The original of the drawings shall be signed by the Engineer and the Contractor as an agreed
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record of the existing ground levels.
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8 A copy transparency of each original drawing will then be given to the Engineer. These
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drawings shall be deemed to be the Contract Drawings replacing the original.
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1.4 MATERIALS TESTING
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Reference should be made to the requirements for the provision of facilities and equipment
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for the testing of materials given in Section 1.
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2 In addition to these requirements the Contractor shall provide a fully equipped site laboratory
or shall arrange for materials and samples to be transported to the Ministry of Environment
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(MOE) for testing or otherwise specified by the Engineer or the Project Documentation.
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3 In addition the Contractor shall provide suitable facilities at the asphalt batching plants to
enable the Engineer to carry out all necessary tests on the raw materials and mixes. Such
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facilities will be subject to the Engineer's approval and the preparation of asphalt mixes shall
not be allowed until the facilities have been approved by the Engineer.
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4 Approved equipment shall be maintained on site at all times to:

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(a) Determine the laying and rolling temperature of bituminous materials.

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(b) Check surface tolerance by using a straightedge and wedges or rolling straightedge.
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(c) Carryout soil grading shape, classification, moisture content and compaction tests, as
required.
(d) Carryout in situ dry density tests.
(e) Carryout bitumen extraction.
5 Equipment shall also be made available when required by the Engineer to take 150 mm
diameter cores from the carriageway.
6 The Engineer may require samples of materials to be delivered to the MOE for additional
tests.
Part 01: General
1.5 NUCLEAR DENSITY TESTING DEVICES
1 No person or company will be permitted to determine in-situ density by mean of a nuclear

density measuring device without complying with the following regulations:
(a) Each device shall have a valid Calibration Certificate issued by the MOE.
(b) Persons operating the device shall hold a valid authorised user certificate issued by the
MOE.
(c) During the operation of the device the person operating it and any assistants shall
wear a suitable film badge or a personal radiation warning alarm. Copies of radiation
exposure report of the film badges should be submitted on monthly basis to the MOE.
1.6 TEMPORARY FENCING
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1 Temporary fencing shall be appropriate to the usage of the adjoining land and unless
otherwise described on the drawings may be of a type selected by the Contractor taking into
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account the usage of the adjoining land subject to the approval of the Engineer.
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2 As soon as the Contractor is placed in possession of any part of the site he shall immediately
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erect fencing on the boundaries of the land as shown on the Drawings. In places where
permanent fencing cannot be erected immediately or where none is required, the Contractor
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shall erect, and when and where required re-erect and maintain, temporary fencing and
subsequently take down and remove as necessary.
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3 The Contractor shall not use barbed wire in areas accessible to the general public. Access
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shall be made in temporary fencing as necessary for the use of the occupiers of adjacent
lands.
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4 If temporary fencing is removed temporarily for the execution of any part of the Works it shall
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be reinstated as soon as possible and in the meantime, subject and without prejudice to the
Conditions of Contract, the gap in the fencing shall be patrolled so that no unauthorised entry
onto adjoining land takes place.
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5 Temporary fencing shall remain in position either until it is replaced by permanent fencing or
until its removal on completion of the Works, unless otherwise described in the contract or
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directed by Engineer.
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1.7 ROAD OPENING
1 Road openings shall be carried out in accordance with the procedures laid down in The Code
of Practice and Specification for Road Openings in the Highway, prepared by the Ministry of
Industry and Public Works, January 1992.
2 Newly compacted bituminous courses shall not be opened to traffic until they have cooled to
ambient temperature. Longer periods may be applied during the summer months for heavily
trafficked roads at the discretion of the supervising engineer
1.8 CONCRETE WORKS
1 All concrete works shall be carried out in accordance with the requirements of Section 5.
Part 01: General
2 Concrete works shall include; mass concrete, reinforced concrete, in-situ concrete, precast
concrete and prestressed concrete.
3 Concrete works shall be deemed to include reinforcement, formwork and all the other
materials procedures and requirements covered by Section 5 - Concrete.
1.9 STANDARDS AND CODES OF PRACTICE
1 The standards, codes of practice and other reference documents referred to in the roadworks
section of the specification are listed in the first clause of each of the parts of the
specification.
2 Unless otherwise agreed with the Engineer a full set of these documents shall be provided by
the Contractor within 30 days of the commencement of the contract. These documents shall
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be kept at the site and shall be available at all times for the use of the Engineer and his staff.
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1.10 TRAFFIC MANAGEMENT
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1 The Contractor shall comply with all instructions given by the Qatar Traffic Police in relation to
traffic management and road safety.
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1.11 ARMED FORCES
1 The Contractor shall comply with all reasonable instructions given by the Qatar Armed
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Forces to allow them access to the Works and with the PWA.
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END OF PART
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Part 02: Site Clearance
2 SITE CLEARANCE .................................................................................................. 2

2.1 GENERAL ............................................................................................................... 2
2.1.1 Scope of Work 2
2.1.2 References 2
2.1.3 Submittals 2
2.2 PROTECTION TO EXISTING SERVICES AND INSTALLATIONS.......................... 3
2.3 RECOVERY OF MATERIALS ................................................................................. 4
2.4 CLEARING AND GRUBBING .................................................................................. 4
2.5 REMOVAL OF STRUCTURES ................................................................................ 5
2.6 REMOVAL OF STREET FURNITURE ..................................................................... 6
2.7 REMOVAL OF FENCES .......................................................................................... 6
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2.8 REMOVAL OF EXISTING PAVEMENTS ................................................................. 6
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2.8.1 General Requirements 6
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2.8.2 Cutting Back Pavement 6
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2.8.3 Stockpiling Asphalt Pavement 7
2.8.4 Stockpile Site 7
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MEASURES FOR STATUTORY UNDERTAKERS .................................................. 8
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2.10 REMOVAL OR TREATMENT TO BURIED UTILITIES ............................................ 8
2.10.1 General 8
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2.10.2 Underground Storage Tanks 8

2.10.3 Removal of Culverts 8
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2.10.4 Abandoned Pipes and Culverts 9

2.10.5 Total Removal of Pipelines 9
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2.10.6 Grouting of Pipelines 9

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2.10.7 Plugging of Pipelines 10

2.10.8 Cut-off Walls and Capping Slabs 10
2.10.9 Manholes and Access Shafts 10
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2.10.10 Drainage Inlets and Gullies 10

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2.11 DISPOSAL OF MATERIALS.................................................................................. 10

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2 SITE CLEARANCE
2.1 GENERAL
2.1.1 Scope of Work
1 This Part includes:
(a) Excavating for, demolishing and removing wholly or in part and disposing of
designated redundant pavements, fences, buildings, culverts, manholes, inlets, gullies,
pipelines or any other obstructions.
(b) Associated earthworks to uncover facilities to be demolished, removed or recovered
and to backfill and compact all trenches, holes, pits or excavations resultant from
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demolition, removal and recovery works.
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(c) Recovering designated materials for storage and reuse.
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(d) Removing and, where required, recovery of designated water, gas and sewage
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pipelines and fittings and of underground cables.
(e) Disposal of materials not recovered.
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Removal of vegetation and surface boulders and rocks.
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2 Related Parts and Sections are as follows:
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This Section: Part 3 Earthworks

Part 5 Asphalt Works
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Part 11 Works in Relation to Services

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Section 2 Building Demolition

Section 5 Concrete
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Section 8 Sewerage
Section 12 Earthworks Related to Buildings
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2.1.2 References
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1 The following standards are referred to in this Part:

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BS 5228......................Code of practice for noise control on construction and demolition sites

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BS 6187......................Code of practice for demolition
The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry
and Public Works.
2.1.3 Submittals
1 Where existing services are to remain and are in close proximity to the works the Contractor
shall submit to the Engineer details of proposed measures to ensure that the existing
services are kept in a safe and stable condition for the duration of the Works.
2 Structures and installations to be dismantled or demolished shall be surveyed by the

Contractor to ascertain exposed constructional dimensions and details. The Contractor shall
prepare sketches of the structures and installations and submit these to the Engineer. This
information shall be used by the Engineer to confirm the scope of the dismantling or
demolition and confirm materials or equipment to be recovered.
3 The method of dismantling and demolition including the sequence of operations and any
special procedural requirements shall be submitted to the Engineer for consideration not less
than seven days before the work is due to begin. Demolition work shall be carried out in
accordance with BS 6187, and the submittal shall include information demonstrating the
Contractor’s proposed methods to attain compliance.
4 Before any blasting operation the Contractor shall submit a detailed method statement for the
work. Blasting work shall be carried out in accordance with The Guide for Civil Users of
Explosives in Qatar, prepared by the former Ministry of Industry and Public Works. Approvals
for blasting work shall be obtained as per the requirements of part 3 of the specification for
rock excavation.
5 The Contractor shall submit for approval his proposed method of grouting pipes to be
abandoned.
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6 Before commencing work on the construction of reinforced concrete cut-off walls and
reinforced concrete capping slabs the Contractor shall submit details for the Engineer's
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approval.
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2.2 PROTECTION TO EXISTING SERVICES AND INSTALLATIONS
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1 The Contractor shall conduct his operations in such a manner as to avoid hazards to
persons, property and vehicles. After work is started on any structure, work on that structure
shall be continued to completion promptly and expeditiously.
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2 Services to unused installations shall be safely disconnected before demolition. Notification

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of disconnection shall be given to the appropriate authorities.

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3 Drains, manholes and gullies that are to remain shall be protected and kept clear of debris at
all times. They shall be left clean and in working order.
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4 Details of any underground caverns, chambers, wells or voids discovered during the
demolition operation shall be reported to the Engineer. Dangerous openings shall be
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protected and illuminated.

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5 Precautions shall be taken to prevent leakage or formation of flammable, explosive,

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unhealthy or environmentally hazardous gas or vapour.

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6 Pits, drains and manholes shall be checked before entry to ensure that the atmosphere is fit
for respiration.
7 The quantity of dust in the atmosphere shall be minimised by spraying the demolition works
with water.
8 The recommendations of BS 5228: Part 2 shall be followed in minimising noise and vibration.
Silencing devices on plant shall be fitted where practicable and ear defenders shall be
provided for site personnel where noisy machinery is used.
9 The location of any survey stations shall be reported to the Engineer. The Engineer may
require the Contractor to transfer existing survey stations to new locations and carry out a
survey to verify the level and co-ordinates of the new survey stations.
10 All existing structures, paving, services, fittings, and other features which are not to be
demolished, dismantled, removed or otherwise dealt with shall be protected from damage by
a means approved by the Engineer.
11 Adjacent structures shall be surveyed for movement, cracks or deformations before and after
demolition. The definition of adjacent structures in this context will be decided by the
Engineer dependent on the type of structure to be demolished and the method of demolition
proposed by the Contractor and the risk of damaging adjacent property.
12 A photographic record of the adjacent structures before and after demolition shall be taken.
13 Where structures, paving, services, fittings or other features are damaged by the Contractor,
they shall be made good to the satisfaction of the Engineer.
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2.3 RECOVERY OF MATERIALS
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1 Where required the Contractor shall recover designated materials without undue damage,
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carry out any required cleaning and shall deliver the recovered materials to locations
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designated by the Engineer and unload and place them into storage.
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Where on-site reuse is designated recovered materials shall be stored on site before their
incorporation in the Works.
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3 Materials to be recovered shall be handled and stored in such a manner as to avoid any
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damage which will impair their reinstallation and reuse. Where the absence of care results in
damage, the Contractor shall repair the damage at his expense. If repairs are deemed to be
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impracticable the Contractor shall provide replacements at his expense.

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2.4 CLEARING AND GRUBBING

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1 The Contractor shall excavate and remove surface material such as debris, windblown sand,
vegetation and any other unsuitable material in the areas and to the thickness instructed by
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the Engineer. Clearing and grubbing shall be restricted to removal of surface material and
debris and shall not include the excavation of natural ground unless directed by the Engineer.
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2 The removed material shall be loaded and transported to an approved dumping area.
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3 All surface objects, trees, stumps, roots and other protruding obstructions not designated to
remain shall be grubbed and cleared as follows:
(a) In areas inside of the grading limits of cut and embankment areas, stumps and non
perishable solid objects shall be cut off not less than one metre below the subgrade
level in the area.
(b) In areas outside of the grading limits of cut and embankment areas, stumps and non-
perishable solid objects shall be cut off not less than 500 mm below finished ground
level.
(c) In areas to be rounded at the top of cut slopes, stumps shall be cut off flush with or
below the surface of the final slope line.
(d) Grubbing of pits and ditches will be required only to the depth necessitated by the
proposed excavation within such areas.
(e) Except in areas to be excavated, stump holes and other holes from which obstructions
are removed shall be backfilled with suitable material and compacted.
(f) Where designated the Contractor shall carefully remove existing trees, plants or
shrubs and carefully transport these to a location designated by the Engineer.
2.5 REMOVAL OF STRUCTURES
1 Unless otherwise directed the Contractor shall demolish and remove all buildings and
structures within the limit of works limits together with all foundations and retaining walls,
piers, partitions and columns down to a plane not less than one metre below the finished
ground level or one metre below the subgrade level in the area.
2 Upon receipt of notification by the Engineer, the Contractor shall take over all responsibility of
the building or buildings then acquired and vacant and shall proceed with the demolition and
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removal thereof.
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3 All structures shall be neatly trimmed off and the reinforcement shall be cut or trimmed off
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close to the concrete and made safe; basement floor slabs shall be broken into pieces;
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excess debris and other foundations, concrete floor slabs, sidewalks, driveways, signs,
sheds, garages, fences and other facilities shall be removed.
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4 The Contractor shall arrange for the discontinuance and disconnection of any services to the
structure or structures in accordance with the requirements of the agency concerned. The
Contractor shall disconnect and properly seal in an approved manner any sewer outlets that
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serve any structure he is to remove. The Contractor shall keep the Engineer informed of his
plans for the performance of any work in connection with the sealing off of such outlets in
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order that proper inspection can be provided at the time the work is performed.
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5 Any additional small out-buildings or temporary structures even if not shown on the Drawings
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shall also be removed if directed by the Engineer.
6 Demolition and removal works shall be carried out mechanically or by hand as necessary in
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such a manner as to cause no undue damage to the public, property, vehicles, pavements,
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services and structures, and the Contractor shall provide temporary works for protection
when necessary, in accordance with any special requirements of the concerned authorities.
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7 Blasting or other operations necessary for the demolition and/or removal of facilities which
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may damage new construction shall be completed before placing the new work, unless
otherwise directed by the Engineer.
8 In all cases the Contractor shall be responsible for all claims resulting from damage, of any
nature, caused by carelessness or negligence on the part of the Contractor, his
subcontractors or agents.
9 Demolition or removal operations for any particular facilities shall not be started until written
approval is obtained from the Engineer.
10 Throughout the demolition period the Contractor shall provide and maintain sufficient and
adequate temporary supports.
2.6 REMOVAL OF STREET FURNITURE
1 Where designated, street furniture shall be recovered, cleaned and either delivered to and
placed into storage at the stores of the designated authority or set aside for re-erection as
part of the Works, or shall be removed and disposed of.
2 The Works shall include the excavation, removal and disposal of all foundations.
3 Before proceeding with the removal of any of the above installations the Contractor shall
contact the relevant authority and obtain approval.
4 The recovery of existing street lighting installations shall form part of the Works and shall be
in accordance with the requirements of the Public Works Authority.
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2.7 REMOVAL OF FENCES
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1 Where designated, fencing, including all support posts, gates, other accessories and
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foundations shall be removed.
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2 The Contractor shall provide suitable termination's for remaining fencing whether inside or
outside the right-of-way limits. nt
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3 Unless otherwise directed all fencing, posts, gates and other accessories shall remain the
property of the Employer and shall be carefully dismantled and delivered to and place into
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storage on site or at the Employer's stores, the location of which shall be obtained from the
Engineer. The supporting posts and supports shall be carefully cleaned of concrete, avoiding
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damage to the posts.

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4 Foundations and sections of fencing which are designated unsuitable for recovery by the
Engineer shall be disposed of.
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2.8 REMOVAL OF EXISTING PAVEMENTS

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2.8.1 General Requirements

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1 On sections of redundant existing roadway (and detours and diversions that are no longer
needed for traffic) the existing pavement structure together with all kerbs, kerb base and
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backing, sidewalk paving, edging or kerb to sidewalk paving including base and backing to
same and other items shall be broken out and removed.
2 Non-asphaltic pavement, kerbs, kerb base and backing, gutters and other associated debris
shall be disposed of unless such items are designated for recovery.
3 Where designated side drainage ditches and excavations shall be filled and the roadway
rough graded to restore approximately the original contour of the ground or to produce
natural, rounded slopes. After the rough grading is completed, the area of the old roadbed
shall be scarified or ploughed to mix the remaining road material thoroughly with earth and
then shall be harrowed and smoothed.
2.8.2 Cutting Back Pavement
1 The Contractor shall cut back all existing construction in such a manner to avoid damage to
the construction which is to remain.
2 Any damage to the existing pavement and other work areas which are to remain shall be
restored to the satisfaction of the Engineer.
3 The details and dimensions of the cutting back of the existing pavement construction shall be
as designated subject to a minimum benching step of 300 mm between each pavement
course.
4 The method of cutting back all existing construction shall be as approved by the Engineer.
5 Once cut back all pavement edges shall be suitably protected against damage from
construction traffic. Any such damage shall be made good before proceeding with pavement
construction.
2.8.3 Stockpiling Asphalt Pavement
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1 During the recovery and stockpiling operations asphalt pavement containing soil or other
debris shall be kept separate from recovered pavement which does not contain soil or other
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debris.
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2 Existing pavement designated for recovery shall be removed and stockpiled by methods
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which will minimise losses and prevent it being contaminated with other materials. Especially,
the Contractor shall ensure that the material is reasonably free of soil and other matter when
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it is stockpiled.
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2.8.4 Stockpile Site

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1 The Engineer may direct that removed asphalt or concrete pavement is stockpiled for
possible future use and the Contractor will transport all removed asphalt or concrete
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pavement to the designated stockpile location.

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2 The Contractor shall inform the Engineer at least seven (7) days before he is ready to
commence stockpiling operations and obtain written approval from the Engineer.
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3 If not previously protected, the Contractor shall provide a protective enclosure around the
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stockpile site to prevent unauthorised dumping by other Contractors and ensure that material
is not removed without authorisation. The protective enclosure around the stockpile site shall
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include a suitable lockable gate for entry.

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4 The Contractor shall assure responsibility for maintenance of the stockpile site during the
time he is depositing and removing material from the stockpile.
5 Maintenance responsibility shall include but not be limited to:
(a) Furnishing plant when directed by the Engineer to spread the material and shape the
stockpile as successive loads of salvaged material are delivered.
(b) Ensuring by whatever means required that no unauthorised dumping is allowed.
(c) Consolidating and reshaping of stockpile from time to time and when final operations
are complete.
6 When directed by the Engineer the Contractor shall permit other contractors access to the
stockpile site to deliver or remove materials.
2.9 MEASURES FOR STATUTORY UNDERTAKERS
1 The Contractor shall take all measures required by any statutory undertaker, the
management of other publicly owned services, or owners of privately owned services or
supplies, for disconnection and proper sealing off of all redundant drains, services and
supplies.
2 The Contractor shall observe and comply with all the safety regulations that are in force for
work associated with various services.
3 Before commencing work on the removal or treatment to any utilities the Contractor shall
contact the statutory undertakers and obtain their written approval.
4 The removal of overhead power lines shall be carried out by the QGEWC or by a specialist
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contractor approved by the QGEWC.
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2.10 REMOVAL OR TREATMENT TO BURIED UTILITIES
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2.10.1 General
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Designated existing underground storage tanks, culverts, box culverts, pipelines, pipes,
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manholes, inlets, gullies and similar facilities for drainage or other designated utilities shall be
totally or partially demolished as designated, all debris removed, the facility thoroughly
cleaned out and the resultant void backfilled with suitable material (as defined in Section 6
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Clause 3.3) and compacted.

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2 Underground utilities, pits, chambers, cesspools and similar facilities shall be demolished to a
depth of one metre below the finished subgrade level in the area, and shall be properly
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cleaned out to full depth and backfilled with approved compacted materials.
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3 Where designated, manhole and access shaft covers and frames and drainage inlet covers
and frames shall be carefully removed, cleaned and transported to and placed into storage at
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designated storage areas.

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4 Materials not recovered for reuse shall be disposed of.

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2.10.2 Underground Storage Tanks

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1 Existing underground storage tanks on the site or under structures designated for removal
shall be removed and disposed of by the Contractor. The Contractor shall take all necessary
precautions during the removal and disposal of any fluid within the tanks and of the tanks
themselves.
2.10.3 Removal of Culverts
1 Where the total demolition of a culvert is designated the culvert top slab, walls, base slab and
all manhole shafts, shall be broken out and all debris removed and disposed of.
2 Where the partial demolition of the culvert is designated the top slab of the culvert shall be
removed together with all manhole shafts. The side walls shall be broken out to the
designated level or to a minimum of one metre below the subgrade level or the finished
ground level in the area. The walls shall he neatly trimmed off and the reinforcement shall be
cut or burned off close to the concrete.
2.10.4 Abandoned Pipes and Culverts
1 Pipes and culverts no longer required which are designated to be abandoned in place shall
either be filled with grout or concrete, as designated by the Engineer.
2 All ends of abandoned pipes with a nominal diameter greater than 100 mm and less than 600
mm and all ends of abandoned culverts with a cross-sectional area of 1.0 m2 or less shall be
plugged by either mass concrete or a reinforced blockwork wall.
3 All ends of abandoned pipes with a nominal diameter of 600 mm or greater and all ends of
abandoned culverts with a cross-sectional area greater than 1.0 m2 shall be provided with a
cut-off wall as designated.
2.10.5 Total Removal of Pipelines
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1 Where designated, pipelines, manholes and fittings together with any plain or reinforced
concrete bed, haunch or surround shall be broken out, removed and disposed of.
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2 Designated pipes and ring fittings to be reused shall be recovered in such a way as to leave
them undamaged and suitable for reuse.
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3 The method of taking apart the pipes and fittings shall be agreed with the Engineer before the
start of the work.
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4 Materials damaged in the process of recovery shall be repaired by the Contractor.

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5 The pipes and fittings recovered shall have all extraneous material including concrete
surround carefully removed, they shall then be thoroughly cleaned and delivered to the
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designated storage area and placed into storage.

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2.10.6 Grouting of Pipelines
1 Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he

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completely filled with a sand-cement grout.

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2 The cement, fine aggregate and water used for the grout shall comply with the requirements
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of section 5 of the Qatar Construction Specification. The sand used for the grout shall be a
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fine graded rounded sand that produces a free flowing grout.
3 The grout shall comprise of one part cement to two parts fine aggregate with enough water to
produce a free flowing and pumpable mix. The use of admixtures to improve the flow and
setting characteristics of the grout will be permitted subject to the prior approval of the
Engineer.
4 Each end of the pipe shall be plugged. No grouting shall commence until the Engineer's
approval has been obtained.
5 The Contractor may propose alternative methods of filling the pipe for the approval of the
Engineer. The Engineer shall retain the right to designate certain pipes that shall be filled with
grout irrespective of any approval to alternative methods of filling.
2.10.7 Plugging of Pipelines
1 Designated pipes shall be plugged by mass concrete as per section 5 of Qatar Construction
Specification to a minimum of one metre lateral extent into the pipe.
2 The method of constructing the plug to ensure a solid watertight seal shall be approved by
the Engineer.
2.10.8 Cut-off Walls and Capping Slabs
1 Where designated the Contractor shall construct a reinforced blockwork cut-off wall to box
culverts and pipelines and a reinforced concrete capping slab to manholes and access
shafts.
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2 Reinforced blockwork cut-off walls shall extend beyond the edges of the pipe and shall be
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founded on a mass concrete of grade 20 as per section 5 of Qatar Construction
Specification.
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2.10.9 Manholes and Access Shafts
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Unless otherwise designated, manholes and access shafts shall be broken out to a plane not
less than one metre below the subgrade level or the finished ground level in the area or to
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immediately below the manhole and/or access shafts cover slab, whichever is the lower.
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2 Manhole and access shaft walls shall be neatly trimmed off and reinforcement shall be cut or
burned off close to the concrete and made safe.
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3 Manholes and access shafts shall be cleaned out and all debris, sediment and refuse and
other unsuitable material disposed of, and backfilled with approved compacted material.
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2.10.10 Drainage Inlets and Gullies
1 Unless shown otherwise, all redundant drainage inlets, gullies and similar facilities shall be
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broken out to full depth.

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2.11 DISPOSAL OF MATERIALS

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1 Materials removed but not recovered shall be disposed of in a lawful manner at approved
dumping areas. The Contractor shall be responsible for obtaining the location of the
dumping area as well as the necessary permits and approvals from the relevant authorities.
END OF PART
QCS 2014 Section 06: Roadworks Page 1
Part 03: Earthworks
3 EARTHWORKS ....................................................................................................... 3
3.1 GENERAL ............................................................................................................... 3
3.1.2 References 3
3.1.3 Definitions 4
3.1.4 Submittals 4
3.1.5 Quality Assurance 6
3.2 EARTHWORKS BY OTHERS ................................................................................. 6
3.3 MATERIALS ............................................................................................................ 6
3.3.1 General 6
3.3.2 Unsuitable Materials 7
3.3.3 Fill and Subgrade Materials 7
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3.3.4 Rock Fill 8
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3.3.5 Water 9
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3.3.6 Performance Indicators 9
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3.4 MAIN PLANT FOR EARTHWORKS ........................................................................ 9
3.4.1 General 9
3.4.2 Compaction Trials nt 10
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3.4.3 Rotary Cultivators 10
3.4.4 Water Sprinklers 10
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3.4.5 Bulldozers 10
3.4.6 Motor Graders 11
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3.4.7 Shovel Tractors 11

3.4.8 Compacting Equipment 11
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3.5 EXCAVATION GENERAL ..................................................................................... 12

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3.5.1 Removal of Unsuitable Soil and Soft Spots 12

3.5.2 Excavating High Level Areas 12
3.5.3 Rock Excavation 13
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3.5.4 Manual Excavation 13

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3.5.5 Excavation for Pits and Trenches 14

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3.5.6 Double Handling 14

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3.6 FILLING GENERAL ............................................................................................... 14

3.6.1 General 14
3.6.2 Filling Around Utilities 15
3.6.3 Fill Supplied by Qatar National Transport Organization (QNTO) 15
3.6.4 Contractors Imported Fill 15
3.6.5 Rock Fill 16
3.6.6 Compaction 17
3.6.7 Filling of Pits and Trenches 18
3.6.8 Work Over Sabkha 18
3.6.9 Trimming Side Slopes 19
3.7 STRUCTURE EXCAVATION AND FILLING .......................................................... 19
3.7.1 General 19
3.7.2 Excavation Supports 20
3.7.3 Dewatering 20
Part 03: Earthworks
3.7.4 Excavation for Structures 20

3.7.5 Use of Materials 21
3.7.6 Cofferdams 21
3.7.7 Backfill Adjacent to Structures 22
3.8 FORMATION PREPARATION............................................................................... 22
3.8.1 Scope 22
3.8.2 Protection 23
3.8.3 Rectification 23
3.9 TOPSOIL ............................................................................................................... 23
3.10 TESTING ............................................................................................................... 23
3.10.1 General 23
3.10.2 Testing Degree of Compaction 24
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3.10.3 California Bearing Ratio 24
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3.10.4 Testing Levels and Evenness of the Formation 25
3.10.5 Testing Formation Works after Completion 25
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Part 03: Earthworks
3 EARTHWORKS
3.1 GENERAL
3.1.1 Scope of Work
1 This Part includes all the earthworks required to construct and maintain the roadway facilities
as follows:
(a) Removing unsuitable materials.

(b) Excavating selected material from the roadway and borrow pits for use as specified.
(c) Placing and compacting of selected material.
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(d) Structure excavation.
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(e) Backfilling.
(f) Supplying and placing topsoil (sweet soil).
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(g) Laying and compaction of fill for shallow embankments where additional slope
protection measures are not required.
2 Related Parts are as follows:

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This Section
Part 1, .............. General
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Part 2, .............. Site Clearance

Part 4, .............. Unbound Pavement Materials
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Part 5, ............. Asphalt Works

Part 6, ............. Concrete Road Pavements
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Part 19, ........... Miscellaneous

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Section 8, Drainage Works

Section 12, Earthworks Related to Buildings
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3.1.2 References
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ASTM D1556 .............Standard Test Method for Density and Unit Weight of Soil in Place by
Sand-Cone Method
ASTM D1557 .............Standard Test Methods for Laboratory Compaction Characteristics of
3 3
Soil Using Modified Effort (56,000 ft lbf/ft (2,700 kN m/m ))
ASTM D4718 .............Standard Practice for Correction of Unit Weight and Water Content for
Soils Containing Oversize Particles
ASTM D1883 .............Standard Test Method for CBR (California Bearing Ratio) of
Laboratory Compacted Soils
ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
soils using Sieve Analysis
Part 03: Earthworks
ASTM D4429 ..............Standard Test Method for (California Bearing Ratio) CBR of Soils in
Place
ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
Content of Soil by the Calcium Carbide Gas Pressure Tester
ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
and Soil-Aggregate by Nuclear Methods (Shallow Depth)
ASTM D1140 ..............Standard Test Method for Amount of Material in Soils Finer than No.
200 (75-μm) Sieve
ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
Using a Straightedge
AASHTO T307 ..........Standard Method of Test for Determining the Resilient Modulus of
Soils and Aggregate Materials
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BS 1377 - Part 3 ........Methods of test for Soils for Civil Engineering Purposes: Chemical and
electro-chemical tests
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3.1.3 Definitions
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1 LSA: Laboratories and Standardization Affairs – Ministry of Environment.
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2 Suitable material: material which is acceptable in accordance with Clause 3.3.3.
3 Imported material: suitable material obtained from outside of the Site.

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4 Optimum moisture content (OMC): the moisture content of soil at which a specified
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compaction effort will produce the maximum dry density when determined in accordance with
ASTM D1557.
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5 Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
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effort at the optimum moisture content when determined in accordance with the modified
compaction test ASTM D1557. Unit weight and moisture content of materials containing more
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than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
corrected following ASTM D4718.
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6 Subgrade: the compacted existing ground or fill for 500mm beneath formation.
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7 Formation: the completed earthworks level shaped in accordance with the Drawings in
readiness to receive the sub-base.
3.1.4 Submittals
1 The Contractor shall submit to the Engineer for approval his proposals for the compaction of
each type of material to be used in embankments detailing the type of plant, number of
passes and maximum loose depth of layer.
2 The contractor shall submit to the Engineer for approval method statements for the following:
(a) Materials production, handling, storage, identification, marking and traceability to

source of production.
(b) Quality assurance and quality control plans for all construction activities.
(c) Quality control testing plan.
Part 03: Earthworks
(d) Equipment and its suitability to fulfill all construction activities to the required quality.
(e) Personnel capability.
(f) Safety and environment preservation measures.
3 Before commencing any structural excavation work greater than 1.5 m in depth, the
Contractor shall submit to the Engineer for his review details of proposals for supporting
excavated faces.
4 The proposals shall be submitted in the form of calculations and drawings which clearly
indicate the extent of excavation at all points along the structure relative to adjacent
properties, roads and services.
5 In the case of supported excavations the proposals shall, for the actual soil properties,
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comprise detailed drawings of the support system stating method of installation and showing
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support member materials, sizes, spacing and engineering calculations to validate the design
of the above, including the maximum theoretical deflections of the support members. The
support system shall be designed in such a manner that no support members extend through
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surfaces exposed in the finished construction and no shoring or bracing is placed under
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permanent structures.
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The engineering calculations shall be in English and shall show lateral earth pressures for the
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full excavation depths, faces at various stages of support during installation and removal and
concrete placement, the anticipated equipment loads, anchorage loads of any description,
the maximum design loads to be carried by various members of the support system and strut
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preload forces.
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7 If the structure support system proposed includes tie-back anchors, the Contractor's
submittal drawings shall show the profile of the soil in which each anchor is to be installed,
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the design load for the full depth of the excavation, the maximum design and proof loads,
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surcharge loads of any description; equipment loads, forces at various stages, support during
installation and removal, and the criteria proposed for deformations under proof loads.
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8 In addition to the approval submittal, shop drawings of the support system are to be
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submitted. Where a proposed system of tie-back anchors projects onto adjoining property
beyond the vertical projection of the designated limits of the Contract, the permission of the
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owner shall be obtained in writing and documentation of such permission shall be included in
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the submittal.
9 Complete working drawings showing the type of dewatering and groundwater control system
proposed shall be submitted for review. The submittal drawings shall show the arrangement,
location and depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedure to be followed shall be shown
together with the standby equipment, standby power supply, and the proposed location or
locations of points of discharge of water. Details of methods of cofferdam construction shall
be included in the submittal.
10 The method and the type of equipment to be used for advancing dewatering wellpoints shall
be submitted for review.
Part 03: Earthworks
3.1.5 Quality Assurance
1 The designs of the structure excavation support systems and the dewatering system shall be
prepared by and signed by a professional engineer specializing in this type of design work.
2 Blasting work shall be carried out by a specialist company with the appropriate license as
detailed in clause 3.5.3.
3.2 EARTHWORKS BY OTHERS
1 Where earthworks have been carried out by others before commencement of the Works, the
Contractor shall carry out all tests he considers necessary to satisfy him that the work already
executed complies with this specification.
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2 Should the Contractor consider the result of the tests unsatisfactory he shall immediately
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provide full details of all such tests carried out for the Engineer's review as to the remedial
work to be undertaken.
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3 The Contractor will be deemed to have satisfied himself as to the adequacy of any previous
earthworks when he proceeds with his own work, and he shall be responsible for repairs to or
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replacement of any defective layer or surface where such failure was due to a fault in the
previously executed work which would have been revealed by normal testing procedures.
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3.3 MATERIALS
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3.3.1 General
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1 All excavated material shall be the property of the Owner and shall not be removed from the
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Site without the written consent from the Owner.

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2 Suitable and approved excavated material from any part of the Site shall be hauled and used
for filling in any other section of the Site. The Contractor shall store such material when
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necessary until the need arises for its use in filling as required by the phases of construction,
or as directed by the Engineer.
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3 Where the amount of suitable material exceeds the amount of fill required for the Works, the
Contractor shall dispose of the surplus material at designated locations. The Contractor shall
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off-load, spread, level, water and carry out other related operations at the disposal site as
directed by the Engineer. The Contractor shall ensure that the disposal site has been
approved by the Municipality concerned.
4 Any excavation greater than the net volume required for the Works in length or width, shall be
made up with suitable compacted fill material at no cost to the Owner and subject to
inspection and approval of the Engineer.
5 Any additional excavation to remove unsuitable material at or below the bottom of foundation
level or construction layers shall be replaced with mass concrete.
6 Before using material resulting from excavation for filling, the Contractor shall carry out field
and laboratory testing to establish the suitability of said material for filling work. Whenever
such excavated material indicates a change in characteristics the Contractor shall carry out
additional testing.
Part 03: Earthworks
7 Where the contract provides for the supply of fill material by others the Contractor shall
remain responsible for checking each load received to ensure that it is in accordance with the
specification requirements and for rejecting unsuitable material. The Contractor shall be
responsible for maintaining all records of deliveries and documentation relating to the quality
of such material.
3.3.2 Unsuitable Materials
1 Unsuitable materials shall mean materials other than suitable materials and include;
(a) Material from marshes.

(b) Tree and plant stumps.
(c) Perishable material.
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(d) Deposits of sabkha with more than 5% water-soluble salts.
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(e) Material subject to spontaneous combustion.
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3.3.3 Fill and Subgrade Materials
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1 The subgrade material and the material used for filling and compacting below the formation
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level of the roadway, sidewalks, hard shoulder, drainage ditches and other areas on site shall
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consist of material approved for filling resulting from the excavation works.
2 In the event that such material is unsuitable or insufficient, the Contractor shall obtain and
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use filling material from borrow pits.

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3 This material shall be clean and free from any unsuitable material and complies with the
requirements listed in Table 3.1.
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4 The maximum particle size of fill material shall be 75 mm unless the material is classified as
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rock as per this part of the specification and the placing and compaction are carried out
according to the requirements for rock fill.
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5 Unit weight and moisture content of materials containing more than 5% by mass of oversize
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fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
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6 When nuclear gauge is used for field density and moisture content testing, 3 readings shall
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be made at each test location within a radius of 2 meters. The average of the 3 readings is
considered to be the density for that test location. Individual density readings shall not be less
than the target relative density by more than 0.5%.
7 Recycled aggregate produced from excavating natural ground and from demolition wastes
can be used for filling purposes provided that the specifications stated in Section 6 - Part 9
are complied.
Part 03: Earthworks
Table 3.1
1
Fill and Subgrade Materials and Construction Specifications
Parameter Standard Specification Limits Minimum Frequency
Percent passing the

ASTM D6913 100%
75mm sieve
Percent passing the
ASTM D1140 30% max.
0.075mm sieve - Each Source
ASTM D4318
Liquid limit 30% max. - Visible change in
Method A
material
Plasticity Index ASTM D4318 10 % max.
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- 1 per 1000 m
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California Bearing
15% min. at 95% MDD
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Ratio (CBR) ASTM D1883
(Soaked)
Swelling 2% max.
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ASTM D6938 - 1 per 200 m
2
per
Field Density Min. 95% of MDD
ASTM D1556 layer
ASTM D6938
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In Place Moisture - 1 every 75m per
2  2% of OMC
Content ASTM D4944 lane per layer
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In Place California 2
ASTM D4429 15% min. 1 per 2000 m
Bearing Ratio (CBR)
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Acid soluble Chloride

BS 1377 Part 3 2% max.
Content
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3
Acid soluble sulphate 1 per 3000 m
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BS 1377 Part 3 3% max.

content
Organic Matter BS 1377 Part 3 2% max.
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Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
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During compaction.
3.3.4 Rock Fill
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1 Rock shall be defined as any naturally formed solid matter encountered in excavation having
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2 2
a crushing strength of not less than 7 N/mm when dry and not less than 4 N/mm after
submergence in water for 24 hours.
2 This shall be determined on samples of 100 mm x 100 mm x 100 mm cubes obtained from
the material (equivalent cores in lie u of cubes may be considered for testing at the discretion
of the Engineer and the method of testing and acceptance criteria will be advised by the
Engineer in such cases).
3 Individual masses of solid material found in excavation and weighing less than 500 kg shall
not be considered as rock.
4 Any artificially formed solid matter such as block work or concrete shall not be considered as
rock.
Part 03: Earthworks
5 The Contractor shall supply any equipment and labor necessary to obtain suitable samples
and carry out testing of rock or suspected rock. The Engineer shall determine the location
and quantity of samples necessary to determine the extent of the rock. These samples shall
be taken in the presence of the Engineer.
6 In the event that the tests prove that the material is rock, the Engineer shall determine the
extent of such material and shall instruct the Contractor accordingly.
3.3.5 Water
1 Potable or brackish water shall be used for all earthwork operations except that only potable
water shall be used for compaction of backfill material within one meter from all surfaces of
the structure and for the backfill of all service trenches.
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2 Brackish water shall have a maximum total dissolved solids (TDS) of 5000 ppm, a maximum
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chloride content of 1500 ppm and a maximum sulphate content (as SO3) of 2000 ppm.
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3.3.6 Performance Indicators
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1 Upon the request of the Engineer, the following performance indicators shall be determined
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from loose in place materials for verification of the pavement structural design following the
AASHTO Mechanistic-Empirical Pavement Design Guide:
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(a) Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture
content and maximum density as per ASTM D1557.
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(b) Parameters and moduli required for determining the Permanent Deformation Potential
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in accordance with AASTHO Mechanistic Empirical Design Guide.

(c) Parameters and moduli required for measuring the Fatigue Cracking Potential for
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stabilized and surface layers in accordance with AASHTO Mechanistic Empirical

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Design Guide.
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2 For performance testing, one sample shall be tested every 10,000 m , and for constructions
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having less than 10,000 m volume, one sample shall be tested every 50% of the total
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volume.
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3.4 MAIN PLANT FOR EARTHWORKS

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3.4.1 General
1 The Contractor shall provide the Engineer with copies of catalogues, technical data and
charts of the machinery to be used on site before the commencement of the work.
2 The Engineer will inspect the machinery and tools before the commencement of work. The
machinery and tools used in carrying out earthworks and other related works for the road
construction and in maintenance of the work shall be in good working condition, and the
Contractor shall maintain them in such condition for the whole duration of the Work.
3 The Contractor shall use power screens equipped with clay reject screen with sufficient
screen area and clay reject conveyor belt when processing subgrade materials. Static
screens shall not be used to produce subgrade materials. Any deviations from this process
must be approved by the Engineer.
Part 03: Earthworks
4 The Contractor shall supply an adequate type and number of machines and tools for the
proper and timely execution of the Works. The number of machines shall not be limited to the
types of equipment or recommended minimum number stipulated in the Contract
Documents, which shall be used for guidance purposes only.
5 The Contract is awarded on the understanding that the actual numbers of machines and
other plant will not be reduced below the numbers shown in the Contract.
6 No plant shall be removed from the site without the specific written approval of the Engineer.
3.4.2 Compaction Trials
1 Before commencing construction of the permanent works, unless otherwise agreed with the
Engineer, the Contractor shall carry out compaction trial, after submitting a method
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statement, for each type of fill material and construction situation of the earthworks to
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establish an approved rolling/compaction procedure which shall then be used as a minimum
requirement for the permanent works unless otherwise directed or agreed by the Engineer.
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2 The compaction trials shall involve all procedures specified for the permanent works
including testing and any equipment, processes or procedures as proposed by the Contractor
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which are not included as a part of these specifications. Compaction trials for each main type
of material shall be carried out on areas having dimensions of approximately 50 meters by 10
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meters.
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3 Construction of the permanent works shall not commence until a compaction procedure has
been approved in writing by the Engineer.
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3.4.3 Rotary Cultivators

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1 Rotary Cultivators shall have axles rotated by a powerful motor and be equipped with metal
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teeth or plates. They shall be designed in such a way as to ensure proper pulverization and
mixing of soil. They must be equipped with apparatus to lift and lower the axles so as to be
always to the required depth.
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3.4.4 Water Sprinklers

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1 Water sprinklers shall be borne by trucks with pneumatic tires and shall be equipped with a
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pressure pump and water sprinkling distribution equipment. The pump shall be powered in
such a manner that the pump pressure will remain uniform regardless of variations in truck
speed. The distributors shall be so designed as to allow sprinkling and adding of water to the
soil uniformly and in controlled quantities and shall be equipped with an approved gauge to
control the quantity of water added during operation. Special spray bar attachments shall be
provided and used in order to sprinkle water on sloped sections. The activation of the water
system shall be controlled from the cab by the driver.
3.4.5 Bulldozers
1 Bulldozers may be tracked or pneumatic-tire vehicles and shall be equipped with a blade for
earth moving and levelling. Ripper attachments shall be provided when necessary. The blade
level shall be hydraulically controlled to raise or lower it so that the work surface can be
formed and adjusted as required.
Part 03: Earthworks
3.4.6 Motor Graders
1 Motor graders shall be pneumatic-tire and shall be equipped such that it is possible to lift,
lower and adjust the angle of the blade as required to control the grading operation and to
perform grading without making undulations.
3.4.7 Shovel Tractors
1 Shovel tractors shall be tractors equipped with a shovel for earth hauling or moving and may
be either on tracks or on pneumatic tires. The shovel shall be hydraulically controlled to raise
and lower it as required.
3.4.8 Compacting Equipment
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1 Rolling compacting equipment shall consist of pneumatic-tire and steel wheeled rollers as
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described below:
(a) Pneumatic-tire rollers shall be equipped with tires of equal size and diameter which
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shall be uniformly inflated so that the air pressure of the tires shall not vary
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significantly, from one another. The wheels shall be spaced so that one pass will
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accomplish one complete coverage equal to the rolling width of the machine. There
shall be a minimum of 6mm overlap between the tracks of the front and rear tracking
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wheels. Self-propelled, pneumatic-tire rollers shall have a minimum weight of
9 tons without ballast and a minimum weight of 18 tons with ballast.
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(b) Steel wheeled rollers shall be of the following types:

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(i) Three-wheeled rollers shall be self-propelled and equipped with a reversing

clutch, a differential drive and with adjustable scrapers to keep the wheel
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surface clean.
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(ii) Tandem rollers shall be self-propelled and equipped with reversing clutches and
adjustable spring scrapers fitted to the driving and steering roller to scrape in
both directions.
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(iii) Vibratory steel tandem rollers shall have the requirements of the foregoing steel
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tandem rollers with a static weight of at least 5000 kg and a vibrating frequency
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between 1500 and 2000 cycles per minute.

(iv) Single drum vibratory steel rollers shall be double axle, self-propelled units with
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the rear axle equipped with pneumatic flotation wheels, they shall have vibrating
frequency capabilities between 1500 and 2000 cycles per minute.
2 Portable vibratory compaction rollers shall be double axle tandem single-drum self-propelled
equipped with a vibrating element delivering an impact of not less than 1590 kg at a
frequency of about 5000 cycles per minute. The roller shall be easily maneuvered, of
adequate width and suitable for rolling ditches with their side slopes having grades of up to
1:3.
3 Hand plate compactors shall be capable of delivering an impact of between 750 to 1500
kilograms.
Part 03: Earthworks
3.5 EXCAVATION GENERAL
3.5.1 Removal of Unsuitable Soil and Soft Spots
1 If during the progress of the work the soil encountered has characteristics, as determined by
tests conducted under the direction of the Engineer, that render it unsuitable for incorporation
in the road embankment, the Contractor shall excavate and remove such unsuitable material
to the extent directed by the Engineer.
2 Where contractor finds isolated soft spots during excavation, this material shall be removed
to the extent directed by the Engineer.
3 No excavated suitable material shall be removed from the Site without the approval of the
Engineer. Should the Contractor be permitted to remove suitable material to suit his
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operational procedure then he shall make good any consequent deficit of fill material arising
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therefrom.
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4 Where the excavation reveals a combination of suitable and unsuitable material the
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excavation shall, unless otherwise agreed with the Engineer, be carried out in such a manner
that the suitable materials are excavated separately for use in the Works without
contamination by the unsuitable material. nt
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5 The hauling of excavated material to areas of fill shall proceed only when sufficient spreading
and compacting plant are operating at the place of deposition to ensure placing and
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compaction.
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6 Unsuitable excavated material shall be removed and carted away to an approved dumping
area after approval from the Engineer.
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7 The Contractor shall replace this unsuitable material by other suitable surplus or imported
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material in layers not exceeding 150 mm compacted thickness to the density specified.
8 If the contractor considers in some situations it is impractical to replace unsuitable material

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with imported material he may elect to use granular material, which shall comply with the
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requirements of part 4 of this specification.

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9 Granular material placed beneath water shall not require compaction, granular material
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placed above water shall be compacted and tested as per the requirements of part 4 of this
specification.
10 If any solution cavities are found in lime stone material they shall be brought to the attention
of the Engineer. The Engineer shall advise what treatment is to be carried out in such
situations.
3.5.2 Excavating High Level Areas
1 The Contractor shall excavate high level areas in all materials including rock for the full width
of the road construction down to the top of the required subgrade.
2 The Contractor shall then scarify a layer not less than 150 mm deep except that this
requirement shall not apply where rock is present.
Part 03: Earthworks
3 The soil shall be pulverized, watered as required, mixed, shaped and compacted to 95 %
maximum dry density, as per ASTM D1557, to a depth of 150 mm.
4 In all excavations the groundwater level shall be maintained at least 300 mm below the
formation level during the works.
3.5.3 Rock Excavation
1 Excavation in rock shall be as defined in clause 3.3.4 of the specification.
2 Excavation in rock may be carried out by a tracked bulldozer and ripper or by the use of
blasting with explosives or any other method approved by the Engineer.
3 Blasting using explosives shall only be permitted if authorized by the civil defense, police and
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any other statutory authority. The Contractor’s method statement shall be agreed before any
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blasting operation.
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4 Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives
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in Qatar prepared by the former Ministry of Industry and Public Works.
5
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For any blasting work involving the use of explosives the Contractor shall use a specialist
company, licensed to carry out such work by the former Ministry of Industry and Public
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Works.
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6 The specialist company shall possess the appropriate license for the required scope of work.
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7 The purchase and delivery of each consignment of explosives for blasting work should be
covered by a separate application for a possession license.
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8 The transportation of explosives shall only be carried out after notification to the police and
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civil defense.
9 For each planned blasting operation the Contractor shall arrange for advance notification to
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be made to the police and civil defense authorities.

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10 After it has been established that the excavated material is rock and after the area where
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such rock exists has been defined, the Contractor shall incorporate the rock in the
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embankment.
11 When excavated material contains more than 25 % of rock larger than 150 mm in greatest
diameter the rock shall be crushed, pulverized and further broken down. The resultant
material from the excavation shall be placed on the embankment in accordance with clause
3.6.5.
3.5.4 Manual Excavation
1 The Contractor shall excavate manually in the vicinity of all services, structures, and any
other areas, and if necessary uncover them, all as directed by the Engineer.
2 The Contractor shall take all precautions to prevent damages to services, properties and
persons, and any damage resulting from the negligence of the Contractor, his agents, or his
employees. Any such damage shall be repaired by the Contractor at his own expense.
Part 03: Earthworks
3.5.5 Excavation for Pits and Trenches
1 All trenches and pits under roads shall, where possible, be excavated, backfilled and
compacted before road construction commences.
2 The sides of the excavation shall be adequately supported at all times.
3 Trenches and pits shall be kept free of water.
4 In tidal and high water table areas the excavation shall be kept free from standing water at all
times during construction.
5 Trenches for pipes or ducts shall be excavated to the levels and gradients indicated in the
contract documents.
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3.5.6 Double Handling
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1 It shall be the Contractor’s responsibility to assess at the start of the contract the quantity of
suitable material available from an excavation for use as fill material and the requirement for
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imported fill material.
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2 The Contractor shall plan earthworks operations to minimize the handling of fill material and
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disruption due to dust and noise from transportation operations.
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3 The Contractor shall not be entitled to any additional payment for double handling of any
excavated material from the site for imported fill.
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4 If it is necessary to double handle the material the Contractor shall take all measures to avoid
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degradation or contamination of fill material.

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5 The Engineer may instruct that the tests to assess the properties of the fill material are taken
at any point during the transportation, placing and compaction process.
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3.6 FILLING GENERAL

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3.6.1 General
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1 Filling low-level areas shall be to the level of subgrade as designated. After completion of
clearing and grubbing, the Contractor shall carry out the necessary levelling in order to
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control the thickness of the layers of fill.
2 The existing natural ground shall then be scarified in place to a minimum depth of 150 mm
for the full width of the embankment except where the material is classified as rock. The
scarified material shall be watered as required, thoroughly mixed, shaped and compacted to
a minimum of 95 % maximum dry density.
3 Where an existing embankment is being widened, the existing embankment slope shall be
trimmed and compacted into benches of minimum width 1m and depth 500mm before
placing and compacting each layer of new embankment material unless otherwise directed
by the Engineer to suit particular circumstances.
4 The Contractor shall not proceed with filling and compacting any subsequent layer before
testing and securing the approval of the Engineer for the previous layer.
5 All fill material for a depth of 500 mm below the formation level must meet the requirements
provided in clause 3.3.3.
Part 03: Earthworks
3.6.2 Filling Around Utilities
1 Filling around culverts, storm water and sewerage pipes, utility and structures, and between
building plot and footpath areas shall be done in accordance with the specific requirements of
the relevant utility authority and the following additional requirements.
2 Filling for these areas shall be from surplus excavated material obtained on site and
approved by the Engineer. In the case of insufficiency of such material then approved
material shall be obtained from borrow pits and filled to the designated levels. The maximum
size of particle allowed in the backfill within one meter of culverts, storm water and sewage
pipes, utilities and structures shall be 25 mm.
3 The Contractor shall take every precaution to protect bridge columns and lighting equipment
when filling between median barriers and any damage to these items arising from the filling
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works shall be repaired by the Contractor.
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4 The Contractor shall agree the type of plant or equipment to be used with the Engineer
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before undertaking this work.
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3.6.3 Fill Supplied by Qatar National Transport Organization (QNTO)
1 nt
If instructed under the projects specification, fill will be imported from other sources using the
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Qatar National Transport Organization (QNTO).
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2 It shall be the responsibility of the Contractor to monitor and control both the quality and the
quantity of this imported fill.
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3 The Contractor shall ensure that all delivery notes for such material are verified and
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authenticated and then collated for submission to the Engineer.

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3.6.4 Contractors Imported Fill
1 The project specifications shall designate areas for the Contractor to obtain borrow material
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for use in the construction of the Works. It is the Contractor's responsibility to satisfy himself
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that there is sufficient borrow material of suitable types.

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2 The Contractor may elect to use alternative sources of borrow material.

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3 It shall be the Contractor's responsibility to obtain all permits or permission and make any
payments that may be required in acquiring the rights to borrow material whether the
Contractor uses the designated areas or elects to use alternative areas. The Contractor shall
ensure that the source of all borrowed material has been approved by the Municipality
concerned.
4 The Contractor shall obtain and supply to the Engineer representative samples from the
borrow pits he intends to use. The Engineer will be afforded the opportunity to be present
during the sampling operations.
5 The Contractor will carry out the necessary laboratory and, if required, field testing to
establish the suitability of the material for filling work and will advise the Engineer of the
results. The Engineer will advise the Contractor whether such material is acceptable and
whether the borrow pit is an approved source of borrow material.
Part 03: Earthworks
6 The Contractor will test samples of the approved borrow pits material actually being imported
onto the site, and should such material fail to meet the requirements of these Specifications,
approval to the use of the borrow pits will be withdrawn and the Contractor shall immediately
cease importation from the borrow pits until such time as the Engineer may approve
alternative sources of material from within the same borrow pits based on sampling and
testing as specified above.
7 The Engineer will decide whether the material already imported from the concerned borrow
pits can remain as placed on the site, or whether the Contractor shall remove and replace the
said material at his own expense.
8 Overburden and any unsuitable top layers at the borrow pit shall be stripped and stockpiled to
the satisfaction of the Engineer. Upon completion of excavation the Contractor shall replace
the overburden and unsuitable material, smooth the surface and leave the area clean and
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tidy to the satisfaction of the Engineer.
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9 The Contractor's haul and traffic arrangements will be subject to the Engineer's approval
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before the work may be commenced.
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3.6.5 Rock Fill
1
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Material consisting predominantly of rock fragments of such a size that it cannot be placed in
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layers of the thickness allowed without crushing, or further breaking down, may be placed in
the embankment in layers not exceeding twice the average size of the larger fragments.
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2 No layer of rock fill shall exceed 800 mm loose thickness.

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3 Rock fill shall be placed and spread so that the largest boulders and fragments are evenly
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distributed, with the voids in-between completely filled with smaller fragments, sand or gravel,
watered in if necessary.
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4 Each layer shall be bladed and leveled by a track laying tractor.

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5 Quality control tests will not normally be performed on this material but each layer must be
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approved in writing by the Engineer before the next is placed.

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6 Embankment layers which consist of material that contains rock but also has sufficient
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compatible finer material other than rock shall be placed and compacted as for soil
embankments. Quality control tests will be made wherever the Engineer determines they are
feasible.
7 Compaction shall be carried out by a vibratory roller with the following minimum mass:
Mass per Meter Width of Depth of Fill Minimum number of Passes of the
Vibration Roll (kg/m) Layer ( mm ) Roller on each Layer
2300 - 2900 400 5
2900 - 3600 500 5
3600 - 4300 600 5
4300 - 5000 700 5
>5000 800 5
Part 03: Earthworks
3.6.6 Compaction
1 The Contractor shall carry out the required compaction specified after grading and leveling
the surface to be compacted. In areas to be filled, compaction shall include adding necessary
soil, water and compacting the first layer in addition to subsequent layers up to the proposed
levels.
2 In areas already excavated down to the required level, compaction shall include adding the
necessary water, and compacting the surface, in accordance with the procedure outlined in
paragraphs 3 to 12 below.
3 After carrying out the grading, leveling, scarifying and pulverizing of the soil layer the
Contractor shall add the necessary amount of water to permeate the pulverized soil.
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4 The soil shall then be thoroughly turned after each addition of water so as to achieve
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homogeneous moisture content in the whole thickness of the layer.
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5 Before compacting, samples of the pulverized soil shall be tested using a 'Speedy Moisture
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Device' (ASTM D4944) or similar instrument to measure the moisture content. If the moisture
content is not within  2 % of the optimum moisture content as determined by ASTM D1557,
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the area represented by this sample shall be scarified and aerated or water added until the
moisture content is within  2 % of the optimum moisture content. The soil shall then be
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primarily leveled in order to commence earth compaction.
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6 After primary levelling referred to above, compaction shall be commenced by means of the
approved rolling pattern.
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7 Filling shall be in layers not exceeding 150 mm compacted thickness.

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8 All areas including embankment roadway, medians, shoulders, sidewalks and verges shall be
compacted to 95 % of Maximum Dry Density as determined by ASTM D1557 unless
otherwise specified or directed by the Engineer.
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9 The rolling shall be carried out in the direction of the road axis until the soil reaches the
required density. In crowned sections, rolling shall start from both edges of the road in the
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direction of the road axis. If the road is super elevated, rolling shall commence from the lower
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side and continue to the higher side. In order to compensate for the amount of water loss in
evaporation during the course of compaction, additional quantities of water shall be added as
required.
10 Each layer shall be levelled and rolled to achieve uniform compaction free from undulations,
soft spots and depressions.
11 No layer shall be covered by the next layer until it has been tested, inspected and approved
by the Engineer.
12 The Contractor shall be responsible for reinstatement to the satisfaction of the Engineer of
any layer damaged or disturbed after compaction and approval, by any means or cause,
before placing the next layer.
Part 03: Earthworks
3.6.7 Filling of Pits and Trenches
1 The bottom of all excavations shall be formed to the lines and levels shown on the drawings.
2 Any pockets of soft soil or loose rock in the bottom of pits and trenches shall be removed and
the resulting cavities and any large fissures filled with suitable material and compacted to a
minimum relative compaction of 95 % based on ASTM D1557.
3 Prior to proceeding with filling, the base of the excavation shall be compacted to a minimum
relative compaction of 95 % based on ASTM D1557.
4 The full width of the compaction plant shall fit inside the surface area of the backfilling with
sufficient space to permit adequate compaction. Under no circumstance shall compaction be
carried out with plant straddling backfilled and existing surfaces.
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tin
5 Trenches and pits shall be backfilled in layers not exceeding 150 mm compacted thickness
unless otherwise directed by the engineer.
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3.6.8 Work Over Sabkha
1
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Where the road embankment passes over Sabkha areas with a high water table the
contractor shall take special precautions during the construction.
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2 These precautions shall include but shall not be limited to the construction of suitable
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temporary haul roads for all construction plant operating in the area.
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3 Haul roads shall be constructed using rock fill and geotextiles as necessary to ensure a safe
stable surface.
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4 The use of geotextiles and geosynthetics shall be in accordance with Part 15 when used for
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the permanent embankment.
5 If directed by the Engineer the Contractor shall construct embankments over Sabkha areas
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with a surcharge of excess material that shall remain in place till all appreciable settlement
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has stopped. The Contractor shall provide a means of monitoring the settlement. The
Engineer shall decide when appreciable settlement has stopped.
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6 Unless a specific treatment in using geotextiles or geosynthetics is described elsewhere in

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the contract, work over Sabkha shall comprise of initially stabilizing the existing Sabkha area
by laying and rolling rock fill layer type 1 according to Table 3.2. This operation should be
continued by adding and rolling type 1 rock fill layer with steel vibratory roller till the layer is
completely stabilized.
7 A layer of geotextile fabric should be laid over the compacted type 1 pervious backfill.
8 A layer of 50mm pervious backfill type 2 according to Table 3.2 should be laid over the
stabilized layer to protect the geotextile fabric.
9 Layer of 200mm thick rock fill type 1 should be laid over type 2 pervious backfill to receive the
required road layers after the above operation.
Part 03: Earthworks
Table 3.2
Definition of Type 1 & 2 backfill materials
Percentage Passing
Size (mm)
Type 1 Type 2
152.0 Max. -
125.0 85 - 100 -
100.0 75 - 90 -
50.0 45 - 65 -
37.5 35 - 55 -
19.0 20 - 35 100
95 – 100
g
12.5 10 - 25
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9.5 5 - 20 70 – 100
4.75 - 0 – 55
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0 – 10
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2.36 -
0.075 - 0–3
3.6.9 Trimming Side Slopes nt

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1 Embankment side slopes shall be trimmed to the profiles and dimensions shown on the
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contract drawings.
The earthworks shall be trimmed to within  20 mm of the designated profile.

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2
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3 The side slopes shall be thoroughly compacted after trimming to ensure a hard surface.
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4 Side slopes shall be tested for compaction in accordance with this part of the specification
and the minimum density requirement shall be 95% of the maximum dry density as per
ASTM D1557.
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3.7 STRUCTURE EXCAVATION AND FILLING

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3.7.1 General
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1 In addition to the work specified, the Contractor shall include all operations necessary to
excavate and backfill as required for the construction of any structure’s installations and
utilities.
2 This work shall include necessary, pumping, dewatering, draining, sheeting, bracing, and the
necessary supply and construction of cribs and cofferdams and their subsequent removal.
3 The Contractor shall take all necessary precautions, to the satisfaction of the Engineer, to
prevent loss of natural cementation in the existing subsoil during, and as a consequence of,
dewatering operations.
4 This work shall also include the furnishing and placing of approved foundation fill material or
concrete to replace unsuitable material encountered below the foundation elevation of
structures.
Part 03: Earthworks
3.7.2 Excavation Supports
1 Battered excavation slopes greater than 1.5 m high shall not be used without the express
written permission of the Engineer. Where such permission is not granted or where only a
part of the overall depth of an excavation is permitted to be with battered slopes all faces of
excavations greater than 1.5 m high shall be supported.
2 The Contractor shall submit his proposals for supporting excavated faces.
3 Before commencing any structural excavation work greater than 1.5 m in depth, the
Contractor shall obtain the Engineer’s approval of his proposals for supporting excavated
faces.
3.7.3 Dewatering
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1 At locations where the excavation extends below the groundwater table, a dewatering system
shall be provided. This will effectively reduce the hydrostatic pressure and lower the
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groundwater levels below excavation levels, as required for the safe and proper excavation of
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the work. It will result in obtaining a stable, dry subgrade for the execution of subsequent
operations.
2 nt
The Contractor shall design dewatering methods and settling basins so that no critical
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amounts of soil, sand or silt are removed during either the initial operations or the
construction operations. Complete working drawings showing the type of dewatering and
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groundwater control system proposed shall be submitted to the Engineer for his review.
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3 The Contractor's submitted drawings shall show the arrangement, location and depths of the
proposed dewatering system if required. A complete description of the equipment and
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materials to be used and the procedure to be followed shall be shown, together with the
standby equipment, standby power supply, and the proposed location or locations of points of
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discharge of water.
4 Any required dewatering system design shall also include the measures taken to prevent
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damage due to settlement of pavement, utilities, sewers, buildings and other structures
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outside the excavation but within the area affected by the dewatering procedures.
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5 Dewatering shall not be terminated without the approval of the Engineer and in the case of
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structures retained by ground anchors dewatering shall not be terminated until the ground
anchors have been stressed to the full working load and approved by the Engineer.
3.7.4 Excavation for Structures
1 The Contractor shall notify the Engineer sufficiently in advance of the beginning of any
excavation so that cross-sectional elevations and measurements may be taken of the
undisturbed ground.
2 Trenches or foundation pits for structures or structure footings shall be excavated to the
designated lines and grades or elevations. They shall be of sufficient size to permit the
placing of structures or structure footings of the full width and length shown. The designated
elevations of the bottoms of footings shall be considered as approximate only and the
Engineer may order, in writing, such changes in dimensions or elevations of footings as may
be deemed necessary, to secure a satisfactory foundation.
Part 03: Earthworks
3 Boulders, logs, and any other unsuitable material encountered in excavations shall be
removed from the site.
4 Unless otherwise designated structure excavation shall be carried out for a width of at least
500 mm beyond the horizontal outside limits of the foundation, footing, box culvert or
structural member to which the excavation relates. Concrete blinding or sub-foundations are
not to be considered as structure for the purpose of defining such excavation.
5 If during the progress of the work, loose or improperly compacted soil or such other material
as the Engineer considers would be detrimental to load distribution of new foundations to the
underlying soil is encountered below the structure foundation level such material shall be
removed within the limits as directed by the Engineer.
6 The resulting void shall be backfilled with either blinding concrete or with suitable material
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compacted to a density not less than 95 % of the maximum dry density as per ASTM D1557.
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The Engineer shall specify the type of backfill to be employed at each location.
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7 After each excavation is completed, the Contractor shall notify the Engineer to that effect,
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and no footing, bedding material or pipe culvert shall be placed until the Engineer has
approved the depth of excavation and the character of the material on which the foundations
will bear. nt
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8 All rock or other hard foundation material shall be cleaned of all loose material and cut to a
firm surface, either level, stepped, or serrated as directed by the Engineer. All seams or
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crevices shall be cleaned and grouted. All loose and disintegrated rock and thin strata shall
be removed. When the footing is to rest on material other than rock, excavation to final grade
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shall not be made until just before the footing is to be placed.

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3.7.5 Use of Materials

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1 All excavated material, so far as it is suitable, shall be used as backfill or roadway fill.
2 All excavated material shall be approved by the Engineer before being used as fill. All surplus
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excavated material and excavated material rejected by the Engineer for use on the site shall
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be removed from the site and disposed of in locations approved by the Engineer.
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3 Where the Engineer designates a disposal location this shall be within a 50 km radius of the
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site of the Works.
3.7.6 Cofferdams
1 Suitable and practically watertight cofferdams shall be used wherever water-bearing strata
are encountered above the elevation of the bottom of the excavation.
2 Cofferdams or cribs for foundation construction shall, in general, be carried well below the
bottoms of the footings and shall be well braced and as nearly watertight as practicable. In
general, the interior dimensions of cofferdams shall be such as to give sufficient clearance
for the construction of forms and the inspection of their exteriors, and to permit pumping
outside of the forms. Cofferdams or cribs which are tilted or moved laterally during the
process of sinking shall be righted or enlarged so as to provide the necessary clearance.
Part 03: Earthworks
3 When conditions are encountered which, as determined by the Engineer, render it

impracticable to dewater the foundation before placing the footing, the Engineer may require
the construction of a concrete foundation seal of such dimensions as he may consider
necessary, and of such thickness as to resist any possible uplift. The concrete for such a seal
shall be placed as directed by the Engineer. The foundation shall then be dewatered and the
footing placed.
4 If weighted cribs are employed and the weight is used to overcome partially the hydrostatic
pressure acting against the bottom of the foundation seal, special anchorage's such as
dowels or keys shall be provided to transfer the entire weight of the crib to the foundation
seal. When a foundation seal is placed under water, the cofferdam shall be vented or ported
at low water level as directed.
5 As an alternative to a cofferdam, the Contractor may propose a wellpoint dewatering system,
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for approval by the Engineer, to keep structural excavation works dry. Such proposal shall
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include, but not be limited to, sufficient calculations, sketches and drawings, to justify the
wellpoint positions and lengths in addition to pumping capacity required. The use of a
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wellpoint dewatering system may not preclude the use of support or shoring within the
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excavation to provide adequate stability and safety to the satisfaction of the Engineer.
3.7.7 Backfill Adjacent to Structures

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1 Excavated areas around structures shall be backfilled with suitable excavated materials or
imported materials as approved by the Engineer. Backfill materials shall be placed in
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horizontal layers not over 150 mm in depth and compacted to a minimum of 95% of the
maximum dry density obtained by ASTM D1557.
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2 Material used for backfill adjacent to structures shall have a sulphate content of less than
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2.5 g/L when tested in accordance with BS 1377.

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3 Each layer shall be moistened or dried as required and thoroughly compacted as specified.
The maximum size of particle allowed in the backfill within one meter of structures shall be 50
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mm.
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4 Backfill and embankment behind walls of any culvert shall not be placed until the top slab of
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the culvert has been placed and cured.

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5 Backfill to culvert walls shall be carried out simultaneously behind opposite walls.
3.8 FORMATION PREPARATION
3.8.1 Scope
1 This work shall consist of the preparation of the graded formation upon which sub-base, base
course or pavement materials are to be placed, all in accordance with these Specifications.
2 All subgrade shall be compacted to the previous requirements of these Specifications.
3 Preparation and surface treatment of the formation shall be carried out after all duct and pipe
installations in the subgrade have been completed.
Part 03: Earthworks
4 Any non-compliant subgrade material shall be excavated, replaced, and compacted to the
required density.
3.8.2 Protection
1 Once prepared, the formation shall be maintained in the finished condition until the first
succeeding course of sub-base, base, or asphalt pavement material has been placed.
2 The Contractor shall take all precautions necessary to protect the formation from damage:
hauling over finished subgrade shall be limited to that which is essential for construction
purposes.
3 Any equipment used for hauling over the prepared subgrade which in the opinion of the
Engineer is causing undue damage to the prepared subgrade or to the underlying materials
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shall be removed from the Works at the request of the Engineer.
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4 All cuts, ruts and breaks in the surface of the subgrade shall be repaired by the Contractor
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before placing any subsequent layer. The Contractor shall protect the prepared subgrade
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from both his own and public traffic.
5
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The Contractor shall maintain the subgrade by blading and rolling as frequently as may be
necessary to preserve the subgrade in a completely satisfactory condition.
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3.8.3 Rectification
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1 Any surface area of the formation which is too high shall be graded off, scarified and re-
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compacted to the full depth of the affected layer.
2 Any surface area of the formation which is too low shall be scarified and corrected by the
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addition of subgrade material of the same classification and moisture content.

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3 The Contractor shall carry out additional testing as required by the Engineer to ensure that
the standard of compaction is satisfactory through the full depth of a layer or previously
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placed layers.
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3.9 TOPSOIL
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1 Topsoil (sweet soil) shall be fertile, free draining, non-toxic soil capable of sustaining healthy
plant growth.
2 The material proposed for use as topsoil shall be approved by the Agricultural Department of
the Ministry of Municipal Affairs and Agriculture.
3 Topsoil shall be loosely placed at the designated thickness.
3.10 TESTING
3.10.1 General
1 For verification of material, moisture content, compaction, thickness and other properties of
the materials or workmanship the Engineer shall at all times have access to all portions of the
works and sites. All sampling and testing of material and work shall be carried out under the
direction of the Engineer.
Part 03: Earthworks
2 The minimum frequency of testing shall follow the frequencies mentioned in Table 3.1 unless
more frequent tests are shown elsewhere in the contract documents or directed by the
Engineer. Other testing shall be carried out as directed by the Engineer.
3.10.2 Testing Degree of Compaction
1 Testing shall be done in accordance with ASTM methods of testing, or other approved
equivalent test or designated procedure.
2 The density-in-place of earthworks layers shall be tested by the sand replacement method
(ASTM D 1556) or nuclear method (ASTM D6938).
3 Nuclear density gauge testing should only be carried out by personnel who have approved
user certification issued by the Ministry of Environment.
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4 Each in-situ density nuclear gauge shall be calibrated and a calibration form issued. The
Contractor shall maintain on site and with the instrument a copy of the Ministry of
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Environment safety and training manual for the use of nuclear density gauges.
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5 When nuclear gauge is used for field density and moisture content testing, the density and
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moisture content for each material shall be verified by measurements in accordance with
ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
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be used as the calibration point value for each material.
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6 When determining the laboratory maximum dry density the method described in ASTM
D1557 shall be applied.
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7 No person or company will be permitted to determine in situ density by means of a nuclear

type density measuring device without complying with the requirements of the Ministry of
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Environment. Refer to clause 1.5 of part 1 of this Section.

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8 The density of any layer requiring compaction shall be determined in accordance with the
specifications mentioned in Table 3.1.
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9 If a layer does not conform to the required density, additional tests may be taken to
determine the limits of the failing area, after which the Contractor shall rework the area until
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the specified density is obtained. The Contractor shall allow enough time in his daily work
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program to permit the performance and checking of the above tests, before he proceeds into
any subsequent operations.
3.10.3 California Bearing Ratio
1 The soaked value of the California Bearing Ratio shall be determined on specimens
compacted at the optimum moisture content and 95 % of the maximum dry density as per
ASTM D1557 after soaking for 4 days in accordance with ASTM D1883. CBR value shall
comply with the minimum requirement as per Qatar Highway Design Manual (QHDM).
2 The test surcharge to be used for the equivalent pavement thickness shall be designated by
the Engineer.
Part 03: Earthworks
3.10.4 Testing Levels and Evenness of the Formation
1 The Engineer shall test the levels and evenness of the finished formation surface to ascertain
compliance.
2 The Contractor shall make available to the Engineer a three-meter straight-edge and a crown
template of sturdy and approved design and the necessary labor to assist in the checking
operations.
3 When tested in accordance with ASTM E1703 by a three-meter straight-edge placed at right
angles to, or parallel to, the road centerline or when tested by a crown template placed
centrally at right angles to the road centerline, the maximum gap between the road formation
surface and the testing edge shall not be greater than 20 mm. Measurements shall be carried
out at maximum spacing of 50m of road length for each lane.
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4 The subgrade shall be prepared to the levels shown on the contract drawings to a tolerance
of between  15 mm and  20 mm when checked by a level instrument.
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5 Variation in the falls to cross-sections of the road shall not exceed 0.4 %.
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These tests shall be made at any point requested by the Engineer. In the event of any failure,
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the Contractor shall correct the unevenness of the surface and resubmit the area for approval
by the Engineer.
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3.10.5 Testing Formation Works after Completion

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1 All completed works shall be inspected at any time as directed by the Engineer in order to
verify the compliance of the executed work to the requirements of the contract as per
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requirement of Part 5 in Section 3.

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END OF PART
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Part 04: Unbound Pavement Materials
4 UNBOUND PAVEMENT MATERIALS ..................................................................... 2

4.1 GENERAL ............................................................................................................... 2
4.1.1 Scope 2
4.1.2 References 2
4.1.3 Definitions 3
4.1.4 Submittals 3
4.2 MATERIALS ............................................................................................................ 4
4.2.1 Sources of Materials 4
4.2.2 Storage and Handling of Materials 4
4.2.3 Inspection Testing and Control 5
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4.2.4 Fine Aggregate 5
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4.2.5 Coarse / Combined Aggregate 6
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4.2.6 Recycled Aggregate 7
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4.2.7 Water 8
4.2.8 Performance Indicators 8
4.3 nt
MAIN EQUIPMENT ................................................................................................. 8
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4.3.1 General 8
4.3.2 Paving Machines 9
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4.3.3 Central Mixers 9

4.4 MIX DESIGNS ......................................................................................................... 9
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4.5 SCREENING AND MIXING ..................................................................................... 9

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4.6 SPREADING AND COMPACTION ........................................................................ 10

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4.7 CORRECTIVE ACTION......................................................................................... 11

4.8 PROTECTION OF SURFACE ............................................................................... 11
4.9 TESTING ............................................................................................................... 12
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4.9.1 General 12
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4.9.2 Thickness 12
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4.9.3 Evenness and Level 12

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4 UNBOUND PAVEMENT MATERIALS
4.1 GENERAL
4.1.1 Scope
1 This Part includes materials, equipment and construction requirements for unbound layers
(aggregate Subbase and Road Base courses).
2 Related Parts are:

Part 1 General
Part 3 Earthworks
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4.1.2 References
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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium
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Sulphate or Magnesium Sulphate
ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size
Coarse Aggregate by Abrasion and Impact in the Los Angeles
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Machine
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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates
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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size

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Machine
ASTM D1556 ..............Standard Test Method for Density and Unit Weight of Soil in Place by
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Sand-Cone Method
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ASTM D1557 ..............Standard Test Methods for Laboratory Compaction Characteristics of

Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))
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ASTM D1883 ..............Standard Test Method for CBR (California Bearing Ratio) of
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Laboratory-Compacted Soils
ASTM D2216 ..............Test Methods for Laboratory Determination of Water (Moisture)
Content of Soil and Rock by Mass
ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
Aggregate
ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4429 ..............Standard Test Method for CBR (California Bearing Ratio) of Soils in
Place
ASTM D4791 ..............Standard Test Method for Flat Particles, Elongated Particles, or Flat
and Elongated Particles in Coarse Aggregate
ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
ASTM D5821 ..............Standard Test Method for Determining the Percentage of Fractured
Particles in Coarse Aggregate
ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
Soils Using Sieve Analysis
ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
Using a Straightedge
AASHTO T307 ...........Standard Method of Test for Determining the Resilient Modulus of
Soils and Aggregate Materials
BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and
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4.1.3 Definitions
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2 Optimum moisture content (OMC): the moisture content of soil at which a specific
compaction effort will produce the maximum dry density when determined in accordance with
the ASTM D1557.
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3 Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
effort at the optimum moisture content when determined in accordance with the modified
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compaction test ASTM D1557. Unit weight and moisture content of materials containing more
than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
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corrected following ASTM D4718.

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4 Subgrade: the compacted existing ground or fill for 500mm beneath formation.
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5 Formation: the compacted subgrade level shaped in readiness to receive the Subbase or
Road Base courses.
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6 Subbase: It is the layer between the subgrade and the Road Base. It consists of compacted
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selected granular materials.

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7 Road Base: It is the layer directly beneath the asphalt course layers and above the subbase
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or subgrade layer. It consists of compacted selected materials. It can be untreated or treated

with suitable stabilizing admixtures.
4.1.4 Submittals
1 The Contractor shall submit recent test results for the proposed sources of materials for all
quality requirements of the Contract. The Contractor shall submit a test certificate that proves
that the raw materials that are purchased/used comply with specifications. The testing may
be performed by an approved private laboratory or by the laboratory associated with the plant
itself.
(a) Materials production, handling, storage, identification, marking and traceability to

(b) Quality assurance and quality control plans for all construction activities.
(c) Materials production, handling, storage, identification and marking, traceability to

(d) Quality control testing plan.
(e) Equipment and its suitability to fulfill all construction activities to the required quality.
(f) Personnel capability.
(g) Safety and environment preservation measures.
1 If requested the Contractor shall arrange for the Engineer to visit the source of the materials
and jointly take samples for testing. The Contractor shall carry out testing as directed by the
Engineer.
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4.2 MATERIALS
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4.2.1 Sources of Materials
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1 The Contractor shall notify the Engineer of the proposed sources of materials. The
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Contractor shall ensure that the sources of all aggregates have been approved by the
Municipality concerned.
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2 The Engineer shall approve the sources before delivery of materials to the site.
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3 Where a proposed source of material is not approved, the Contractor shall propose an
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alternative source of material.
4.2.2 Storage and Handling of Materials

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1 Materials shall be so stored and handled as to assure the preservation of their quality and
fitness for use in the works. Even after source approval has been given materials may again
be inspected and tested before use in the work.
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2 Stored material shall be located so as to facilitate prompt inspection.

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3 All storage sites shall be restored to their original condition before acceptance of the Works.
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4 Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
or contamination of the various sizes. Stockpiles shall be kept flat, and the formation of high
cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling
aggregates the Engineer may require the use of baffled chutes or perforated chimneys.
5 When trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at
a time with trucks depositing their loads as close to the previous load as possible. The use of
tractors or loaders to push material deposited at one location to another location in the
stockpile shall not be allowed during the construction of the stockpile and their use shall be
limited to levelling the deposited material only.
6 The Contractor shall take all necessary protection measures in the storage, handling and
stockpiling of materials to prevent contamination of materials by dust. The measures that the
Contractor proposes to take shall be subject to the approval of the Engineer.
4.2.3 Inspection Testing and Control
1 Loose materials for testing and acceptance shall be sampled from the un-compacted in-place
layer.
2 For verification of plant weights and measures, character of materials used in the preparation
of the mixes, testing and other quality control requirements, the Engineer shall at all times be
provided access to all portions of the mixing plant, aggregate plant, storage yards, crushers
and other facilities used for producing and processing the materials of construction.
3 The Engineer shall have authority to take samples and perform tests on any material
supplied to the site from any source whatsoever in order to establish compliance and to
accept or reject as he deems necessary. Samples shall also be taken from completed work
to determine compliance. The frequency of all sampling and testing shall be as designated by
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the Engineer.
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4 The Contractor shall provide suitable facilities at the quarry or plants to carry out all
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necessary tests on the raw materials and mixes.
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5 The Contractor shall arrange for obtaining specimens of materials and samples taken from
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stockpiles, including the provision of any necessary equipment and plant. This work shall be
performed in the presence of the Engineer if so directed by the Engineer.
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6 Materials that are not in compliance shall be rejected and removed immediately from the site
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of the works unless otherwise instructed by the Engineer.

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7 Where defects in the materials or the completed work have been corrected, the Contractor
shall not proceed with subsequent work until approval has been given by the Engineer.
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4.2.4 Fine Aggregate

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1 Fine aggregate (passing the 4.75 mm sieve) shall consist of crushed mineral aggregate
and/or natural sand.
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2 The fine aggregate shall be clean and free from clay-balls and other extraneous or
detrimental materials.
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3 Where the source of fine aggregate does not meet the requirements listed in Table 4.1, the
Contractor may, with the Engineer's approval, add fine aggregate and filler to correct the
gradation or to change the characteristics of the material passing the 0.425mm sieve so as to
meet the requirements. Such additional material shall be added in a manner which ensures a
completely homogeneous material.
Table 4.1
Specifications of fine aggregates for Road Base and Subbase layers
Specification Limits
Parameter Standard Minimum Frequency
Road Base Subbase
Liquid Limit ASTM D4318 25%max. 25% max.
- Each source
Plasticity Index ASTM D4318 6 % max. 6 % max.
- Visible change in material
3
Sand equivalent ASTM D2419 35 min. 25 min. - 1 test every 1000m
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Organic content BS 1377
0.5% max. 0.5% max.
Part 3
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4.2.5 Coarse / Combined Aggregate
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Coarse aggregate (retained on the 4.75 mm sieve) shall consist of crushed stone or crushed
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gravel and shall be free from organic matter, clay and other extraneous or detrimental
materials.
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2 The required properties of coarse aggregates for Road Base and Subbase layers are listed in
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Table 4.2.
Table 4.2
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Specifications of coarse aggregates for Road Base and Subbase layers

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Road Base Subbase
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Fractured Faces ASTM D5821 50% min. 50% min.

- Each source
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Flat and Elongated

ASTM D4791 10% max. 15% max.
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Particles (5:1) - Visible change in
ASTM C131 material

Loss by Abrasion 30% max. 40% max.
ASTM C535 3
- 1 test every 3000m
Soundness
ASTM C88 15% max. 20% max.
(5 cycles by MgSO4)
3 Loose materials for testing and acceptance shall be sampled from the un-compacted in-
place layer.
4 The required properties of combined aggregate for Road Base and Subbase layers are listed
in Table 4.3.
5 Unit weight and moisture content of materials containing more than 5% by mass of oversize
fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
6 When nuclear gauge is used for field density and moisture content testing, 3 readings shall
be made at each test location within a radius of 2 meters. The average of the 3 readings is
considered to be the density for that test location. Individual density readings shall not be less
than the target relative density by more than 0.5%.
7 When nuclear gauge is used for field density and moisture content testing, the density and
moisture content for each material shall be verified by measurements in accordance with
ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
be used as the calibration point value for each material.
8 In case abnormally high relative density values are encountered, it will be required to re-
evaluate the related field and laboratory density values.
9 Gradation requirements of combined aggregate for Road Base and Subbase layers are listed
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in Table 4.4.
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4.2.6 Recycled Aggregate
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1 Recycled aggregate produced from excavating natural ground and from demolition wastes
can be used in subgrade and subbase layers provided that the specifications stated in
Section 6 - Part 9 are complied.
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Table 4.3
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Specifications of combined aggregates for Road Base and Subbase layers
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Road Base Subbase

3 3
2.15 Mg/m 2.05 Mg/m
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Maximum Dry Density ASTM D1557 - Each source.

min. min.
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Gradation ASTM D6913 Table 4.4 Table 4.4 - Visible change in

California Bearing material
ASTM D1883 80% min. 70% min.
Ratio (CBR)
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(Soaked) - 1 test per 1000m
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Swelling 0.5% max. 1.0% max.

ASTM D6938 2
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Field Density 100% of MDD 100% of MDD - 1 per 200 m per

ASTM D1556 layer
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In Place Moisture ASTM D6938 - 1 every 75m per

2  1.5% of OMC  2% of OMC lane per layer
Content ASTM D4944
In Place California 2
ASTM D4429 80% min. 70% min. 1 per 2000 m
Bearing Ratio (CBR)
Acid soluble Chloride
BS 1377 Part 3 2% max. 2% max.
Content 3
1 per 3000 m
Acid soluble sulphate
BS 1377 Part 3 3% max. 3% max.
content
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Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
2
During compaction.
Table 4.4
Gradation limits for Road Base and Subbase layers
Sieve Size Road Base Subbase
50.0 mm 100 100

37.5 mm 95 – 100 90 – 100
19.0 mm 70 – 92 70 – 90
9.5 mm 50 – 70 45 - 75
4.75 mm 35 – 55 30 – 60
0.600 mm 12 – 25 10 – 30
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0.075 mm 0–8 0 – 12
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4.2.7 Water
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1 Sea, brackish or saline water shall not be used in the mixing, spreading and compacting
operations for Road Base / Subbase layers.
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4.2.8 Performance Indicators
1 Upon the request of the Engineer, the following performance related indicators shall be
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determined from loose in place materials for verification of the pavement structural design
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following the AASHTO Mechanistic-Empirical Pavement Design Guide:
(a) Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture
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content and maximum density as per ASTM D1557.

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(b) Parameters and moduli required for determining the Permanent Deformation Potential
in accordance with AASTHO Mechanistic Empirical Design Guide.
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(c) Parameters and moduli required for measuring the Fatigue Cracking Potential for
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stabilized and surface layers in accordance with AASHTO Mechanistic Empirical

Design Guide.
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2 For performance testing, one sample shall be tested every 10,000 m , and for constructions
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having less than 10,000 m volume, one sample shall be tested every 50% of the total
volume.
4.3 MAIN EQUIPMENT
4.3.1 General
1 Unless otherwise stipulated herein the provisions of Section 6, Part 3 (Earthworks), in respect
of the main machinery and tools used in earthworks construction, shall be adhered to,
subject to the modifications and additions in this clause.
2 The Contractor shall not be allowed to use any equipment or plant before obtaining the
approval of the Engineer, and the Contractor shall undertake sound technical methods in
operation and to engage skilled and trained operators, mechanics and labor to carry out the
works.
3 The Engineer shall have the right to stop the use of any equipment or plant which he deems
to be inferior to the quality required and to instruct the removal of such equipment and to
have it replaced by suitable equipment or to alter the method of operation at any time he so
desires.
4 The Contractor shall immediately comply with such instructions without being entitled to any
indemnities or extensions as a result of such instructions.
5 The Engineer shall have the right to expel any operators, mechanics or labor and to instruct
suitable replacement thereof at any time he deems such action is necessary.
4.3.2 Paving Machines
1 Paving machines shall be self-propelled and shall be capable of spreading the Subbase and
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Road Base materials in one operation so as to make it ready for compaction with minimum
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shaping.
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2 The paving machines shall be provided with a screed that strikes off and distributes the
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material to the required width and level.
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The width of each spread shall not be less than a traffic lane wide.
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4 The screed shall be adjustable to the required width being laid.
5 Screed action includes any practical motion that produces a finished surface texture of
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uniform appearance.
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4.3.3 Central Mixers

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1 A central mixing plant shall be either of an approved drum or pugmill type with a moisture
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control system so that the material may be spread without further mixing or processing.
2 Means shall be provided for regulating the flow of material to the mixer. The various feeds
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shall be calibrated to allow adjustments to the mix design to be carried out.

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4.4 MIX DESIGNS

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1 Aggregate Subbase and Road Base courses shall consist of crushed mineral aggregates or
natural mineral aggregates of the designated gradation and thickness.
2 The maximum dry density and the optimum moisture content of the material shall be
ascertained as per the test procedure given in ASTM D1557 and this shall be used to assess
the degree of compaction of the mix after rolling.
3 The pavement layer designated as sub-base may be substituted by any of the materials
designated to be laid on it subject to the approval of the Engineer.
4.5 SCREENING AND MIXING
1 Screening shall be required for the materials used in Subbase and Road Base courses to
ensure that the designated gradation is attained.
2 Screens shall be of the size and number required to remove oversize aggregate and to
separate the materials into two or more fractions so that they may be combined to meet the
required gradation.
3 A central mixing plant shall be used for the mixing of materials.
4 Mixing of separate materials on the roadway by motor grader will not be permitted.
4.6 SPREADING AND COMPACTION
1 Before commencing the construction of the Subbase and Road Base courses, a written
approval for the Engineer must be obtained that the subgrade is in compliance.
2 The optimum moisture content of the material shall be noted from the mix design and the
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actual moisture content determined at the plant after mixing.
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3 If the natural moisture content is less than the optimum moisture content, the necessary
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amount of water must be added to obtain the optimum content.
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4 Allowance shall be made for the quantity of moisture which may be lost by evaporation in the
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process of raking, levelling and compacting, depending on atmospheric temperature.
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5 The compacted layer shall have moisture content within  1.5% of the optimum moisture
content for Road Base layers and within  2% for Subbase layers.
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6 The moisture content shall be uniform in all parts of the section where the work is being
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carried out and in the various depths of the layer thickness.

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7 Subbase and Road Base courses shall be laid by a paving machine with a spreader box.
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8 Loose samples of materials for testing and acceptance shall be obtained from behind the
paving machine upon the approval of the Engineer.
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9 Compaction shall start immediately the material has been laid and as per the approved rolling
pattern.
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10 Work on the Subbase and Road Base courses shall not be permitted during rainy weather.
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11 Material shall be spread to a thickness that would result in layers not more than 150 mm thick
after compaction. Where the finished compacted thickness exceeds 150 mm placing shall
be executed in composite layers each layer not exceeding 150 mm in compacted thickness
as directed by the Engineer.
12 The course shall not be rolled when the underlying material is soft or yielding or when the
rolling causes a wave-like motion in this course.
13 When the rolling develops irregularities, the irregular surface shall be loosened, then refilled
with the same kind of material as used in constructing the course and again rolled.
14 Along places inaccessible to rollers, the Subbase and Road Base courses material shall be
tamped thoroughly with suitable mechanical tampers to achieve the required density and
finish.
15 Rolling must continue until a relative density of not less than 100 % of the maximum dry
density has been obtained as determined by the moisture-density relationship in ASTM
D1557.
16 Care shall be taken so that layers already compacted under the layer being executed are not
damaged, or that the formation is not damaged.
17 This aspect must be given special attention in places where rolling equipment makes turns to
change direction.
18 Any such damage resulting in mixing the various layers constituting the different subgrades,
Subbase and Road Base courses shall be carefully made good by the Contractor at his own
expense and to the satisfaction of the Engineer.
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4.7 CORRECTIVE ACTION
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1 Any material that fails to meet test requirements shall either be reworked or removed and
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replaced and then retested to check for compliance.
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2 Any soft spots, irregularities or depressions that develop in the surface of the Subbase or
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Road Base courses, shall either be corrected by loosening the surface of such areas and
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adding further material, or by removing the material in such areas and replacing with further
approved material.
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3 In the event of heave occurring during compaction, caused either by excessive build-up of
pore water pressure or the groundwater table being sufficiently high to affect construction
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techniques, either of the following procedures shall be adopted subject to the approval of the
Engineer:
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(a) Sufficient time shall be allowed to elapse enabling the excess pore water to dissipate
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before further construction or compaction is carried out

(b) The affected material shall be removed, and approved alternative construction layers
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substituted.
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4 For correction of low density or incorrect level, the top 75 mm shall be scarified, reshaped
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with material added or removed as necessary and re-compacted to the designated

requirement. The area treated shall not be less than 30 metres long and 2 metres wide or
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such area determined by the Engineer as necessary to attain compliance.
5 Where the surface of the sub-base is covered in a very thin smooth skin composed of fine
particles cemented together acting as a barrier to the prime coat the top 75 mm shall be
scarified, reshaped, watered if necessary, and re-compacted prior to the application of prime
coat.
6 The Contractor shall carry out additional testing if required by the Engineer to ensure that the
standard of compaction is satisfactory through the full depth of the layer.
4.8 PROTECTION OF SURFACE
1 The Contractor shall protect the Subbase and Road Base courses so that it shall be
maintained sound during work progress, after its completion and before receiving the
bituminous layers or before laying the surface overlay thereon.
2 Any damage caused to the layer if exposed to traffic or natural conditions resulting in damage
to its surface shall be made good at the expense of the Contractor and to the satisfaction of
the Engineer.
3 The Engineer has the right to stop all hauling over completed or partially completed Subbase
and Road Base courses when in his opinion such hauling is causing damage.
4 Following the completion of the Subbase or Road Base courses the Contractor shall perform
all maintenance work necessary to keep the course in a condition for priming.
4.9 TESTING
4.9.1 General
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1 Loose materials for testing and acceptance shall be sampled from the un-compacted in-place
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layer.
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2 All testing shall be conducted in accordance with ASTM, AASHTO and BS standards listed in
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section 4.2.
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Testing frequency for the properties of Subbase or Road Base layers are listed in Tables 4.1,
4.2 and 4.3.
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4 At any stage in the mixing, transportation, spreading or compaction process, the Engineer
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may instruct that these tests are carried out.

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5 Before the application of any prime coat or any other paving course, the aggregate Subbase
or Road Base courses shall have been tested for compliance with the requirements of this
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clause on testing and approved by the Engineer.

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4.9.2 Thickness
1 The thickness of the material shall be derived from checking the level by dipping from string
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lines stretched across the roadway between pins or kerbs. Unless agreed otherwise with the
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Engineer dipping shall be carried out at intervals of not less than 10m.
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2 The thickness of the material shall be measured at the location where the material is
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removed from the roadway for gradation analysis.
3 Wherever the thickness of compacted aggregate Subbase or Road Base courses is found to
vary from the thickness specified in the project drawings or specification by more than 10 %
the area involved shall be satisfactorily corrected to provide the required thickness
constructed to the designated grade level.
4.9.3 Evenness and Level
1 The final surfaces of the Subbase or Road Base courses shall be tested by means of a 3
meter long straight edge in accordance with ASTM E1703 and no rises or depressions in
excess of 10 mm shall appear in the surface. Measurements shall be carried out at
maximum spacing of 30m of road length for each lane.
2 The finished surface shall also be checked by dips or spot levels and shall be constructed to
the designated grade levels to within  10 mm.
3 Where these requirements are not met, the Contractor shall determine the full extent of the
area which is out of tolerance and shall make good the surface of the course by scarifying to
a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater,
reshaping by adding or removing material as necessary, adding water if necessary and re-
compacting.
END OF PART
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Part 05: Asphalt Works
5 ASPHALT WORKS.................................................................................................. 3
5.1 GENERAL ............................................................................................................... 3
5.1.1 Scope 3
5.1.2 References 3
5.1.3 Definitions 7
5.1.4 Submittals 7
5.2 MATERIALS ............................................................................................................ 8
5.2.1 Unacceptable Materials 8
5.2.2 Fine Aggregate 9
5.2.3 Coarse Aggregate 9
5.2.4 Recycled Aggregate 10
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5.2.5 Mineral Filler 10
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5.2.6 Asphalt Binder 11
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5.2.7 Prime Coat 13
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5.2.8 Tack Coat 13
5.2.9 Delivery, Storage and Handling 13
5.2.10 Inspection and Control
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5.3 MARSHALL MIX DESIGN ..................................................................................... 14
5.3.1 General 14
5.3.2 Marshall Mix Design Criteria 15
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5.3.3 Quality Control Testing 17

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5.4 DENSE BITUMEN MACADAM .............................................................................. 20

5.5 SUPERPAVE MIX DESIGN ................................................................................... 22
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5.6 PERFORMANCE EVALUATION OF ASPHALT CONCRETE ................................ 24

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5.7 DELIVERY, SPREADING AND FINISHING ........................................................... 25

5.7.1 Delivery of Mixes 25
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5.7.2 Spreading and Finishing 25

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5.7.3 Compaction of Mixes 26

5.7.4 Transverse Joints 27
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5.7.5 Longitudinal Joints 28

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5.7.6 Paving Edges 28

5.7.7 Breakdown Rolling 28
5.7.8 Intermediate Rolling 29
5.7.9 Finish Rolling 29
5.7.10 Protection of Laid Courses 29
5.8 COLD PLANING .................................................................................................... 29
5.9 PRIME COAT ........................................................................................................ 30
5.9.1 General 30
5.9.2 Equipment Required 30
5.9.3 Surface Preparation 30
5.9.4 Application 30
5.9.5 Maintenance and Traffic 31
5.10 TACK COAT .......................................................................................................... 31

5.10.1 General 31
5.10.3 Surface Preparation 32
5.10.4 Application 32
5.10.5 Maintenance and Traffic 32
5.11 THICKNESS AND LEVEL...................................................................................... 32
5.11.1 Thickness 32
5.11.2 Transverse Evenness 33
5.11.3 Evenness and Rideability 33
5.12 PAVEMENT EVALUATION TECHNIQUES ........................................................... 35
5.13 PRODUCTION OF ASPHALT CONCRETE COURSES ........................................ 35
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5.13.1 Weather Limitations 35
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5.13.3 Survey and Preparation 35
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5.13.4 Heating of Asphalt Binder 36
5.13.5 Heating of Mineral Aggregate 36
5.13.6 Proportioning and Mixing
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5.14 HAULING EQUIPMENT......................................................................................... 37
5.15 OTHER EQUIPMENT ............................................................................................ 37
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5.15.1 Spreading and Finishing Equipment 37

5.15.2 Rolling Equipment 38
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5.15.3 Liquid Asphalt Distributor 39

APPENDIX .......................................................................................................................... 40
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5 ASPHALT WORKS
5.1 GENERAL
5.1.1 Scope
1 Materials, equipment, and construction of bituminous paving works including prime coating
and tack coating.
2 Related Parts
Part 1, ............. General

Part 3, ............. Earthworks
Part 4, ............. Unbound Pavement Materials.
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5.1.2 References
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1 The following standards and other documents are referred to in this Part:
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ASTM C40 ..................Standard Test Method for Organic Impurities in Fine Aggregates for
Concrete
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ASTM C50 ..................Standard Practice for Sampling, Sample Preparation, Packing and
Marking of Lime and Limestone Products
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ASTM C51 ..................Terminology Relating to Lime and Limestone (as used by the industry)
ASTM C88 .................Standard Test Method for Soundness of Aggregates by Use of Sodium
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Sulphate or Magnesium Sulphate

ASTM C117 ................Standard Test Method for Materials Finer than 75-μm (No. 200) Sieve
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in Mineral Aggregates by Washing

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ASTM C127 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
and Absorption of Coarse Aggregate
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ASTM C128 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
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and Absorption of Fine Aggregate

ASTM C131 ...............Standard Test Method for Resistance to Degradation of Small Size
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Machine
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ASTM C136 ...............Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates
ASTM C142 ...............Standard Test Method for Clay Lumps and Friable Particles in
Aggregates
ASTM C150 ................Specifications for Portland Cement
ASTM C535 ...............Standard Test Method for Resistance to Degradation of Large Size
Machine
ASTM D5 ....................Standard Test Method for Penetration of Bituminous Materials
ASTM D6 ....................Standard Test Method for Loss on Heating of Oil and Asphaltic
Compounds
ASTM D36 ..................Standard Test Method for Softening Point of Bitumen (Ring-and-Ball
Apparatus)
ASTM D75 .................Standard Practice for Sampling Aggregates

ASTM D92 .................Standard Test Method for Flash and Fire Points by Cleveland Open
Cup Tester
ASTM D113 ................Standard Test Method for Ductility of Bituminous Materials
ASTM D140 ...............Standard Practice for Sampling Bituminous Materials
ASTM D242 ................Standard Specification for Mineral Filler for Bituminous Paving
Mixtures
ASTM D402 ................Standard Test Method for Distillation of Cutback Asphaltic
(Bituminous) Products
ASTM D546 ................Standard Test Method for Sieve Analysis of Mineral Filler for
Bituminous Paving Mixtures
ASTM D946 ...............Standard Specification for Penetration Graded Asphalt Cement for
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Use in Pavement Construction
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ASTM D977 ................Standard Specification for Emulsified Asphalt
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ASTM D979 ................Standard Practice for Sampling Bituminous Paving Mixtures
ASTM D995-95...........Standard Specification for Mixing Plants for Hot-Mixed, Hot-Laid
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ASTM D1188: ............Standard Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using Coated Samples
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ASTM D2027 ..............Standard Specification for Cutback Asphalt (Medium-Curing Type)
ASTM D2041 .............Standard Test Method for Theoretical Maximum Specific Gravity and
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Density of Bituminous Paving Mixtures

ASTM D2042 ..............Standard Test Method for Solubility of Asphalt Materials in
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Trichloroethylene
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ASTM D2172 .............Standard Test Methods for Quantitative Extraction of Bitumen from
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ASTM D2419 .............Standard Test Method for Sand Equivalent Value of Soils and Fine
Aggregate
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ASTM D2726 .............Standard Test Method for Bulk Specific Gravity and Density of Non
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Absorptive Compacted Bituminous Mixtures

ASTM D2872 .............. Standard Test Method for Effect of Heat and Air on a Moving Film of
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Asphalt (Rolling Thin Film Oven Test)

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ASTM D2950 ..............Standard Test Method for Density of Bituminous Concrete in Place by
Nuclear Methods
ASTM D2995 ..............Standard Practice for Estimating Application Rate of Bituminous
Distributors
ASTM D3319 ..............Standard Practice for the Accelerated Polishing of Aggregates Using
the British Wheel
ASTM D3549 ..............Standard Test Method for Thickness or Height of Compacted
Bituminous Paving Mixture Specimens
ASTM D4318 .............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4402 .............Standard Test Method for Viscosity Determination of Asphalt at
Elevated Temperatures Using a Rotational Viscometer
ASTM D4791 .............Standard Test Method for Flat Particles, Elongated Particles, or Flat
and Elongated Particles in Coarse Aggregate
ASTM D5361 ..............Standard Practice for Sampling Compacted Bituminous Mixtures for
Laboratory Testing
ASTM D5444 ..............Standard Test Method for Mechanical Size Analysis of Extracted
Aggregate
ASTM D5546 .............Standard Test Method for Solubility of Asphalt Binders in Toluene by
Centrifuge
ASTM D5581 ..............Standard Test Method for Resistance to Plastic Flow of Bituminous
Mixtures Using Marshall Apparatus (6 inch-Diameter Specimen)
ASTM D5821 .............Standard Test Method for Determining the Percentage of Fractured
Particles in Coarse Aggregate
ASTM D6307 ..............Standard Test Method for Asphalt Content of Hot-Mix Asphalt by
Ignition Method
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ASTM D6373 ..............Standard Specification for Performance Graded Asphalt Binder
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ASTM D6521 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a
Pressurized Aging Vessel (PAV)
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ASTM D6648 .............Standard Test Method for Determining the Flexural Creep Stiffness of
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Asphalt Binder Using the Bending Beam Rheometer (BBR)
ASTM D6723 ..............Standard Test Method for Determining the Fracture Properties of
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Asphalt Binder in Direct Tension (DT)
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ASTM D6926 .............Standard Practice for Preparation of Bituminous Specimens Using
Marshall Apparatus
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ASTM D6927 ..............Standard Test Method for Marshall Stability and Flow of Bituminous
Mixtures
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ASTM D6931 ..............Standard Test Method for Indirect Tensile (IDT) Strength of
Bituminous Mixtures
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ASTM D7173 .............Standard Practice for Determining the Separation Tendency of

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Polymer from Polymer Modified Asphalt

ASTM D7175 .............Standard Test Method for Determining the Rheological Properties of
Asphalt Binder Using a Dynamic Shear Rheometer
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ASTM D7405 .............Standard Test Method for Multiple Stress Creep and Recovery
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(MSCR) of Asphalt Binder Using a Dynamic Shear Rheometer

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ASTM E11 .................Standard Specification for Woven Wire Test Sieve Cloth and Test
Sieves
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ASTM E274 ................Standard Test Method for Skid Resistance of Paved Surfaces Using a
Full-Scale Tire
ASTM E303 ................Standard Test Method for Measuring Surface Frictional Properties
Using the British Pendulum Tester
ASTM E950................. Standard Test Method for Measuring the Longitudinal Profile of
Travelled Surfaces with an Accelerometer Established Inertial Profiling
Reference
ASTM E965 ................Standard Test Method for Measuring Pavement Macrotexture Depth
Using a Volumetric Technique
ASTM E1926............... Standard Practice for Computing International Roughness Index of
Roads from Longitudinal Profile Measurements
AASHTO M82.............Standard Specification for Cutback Asphalt (Medium-Curing Type)

AASHTO M92.............Standard Specification for Wire-Cloth Sieves for Testing Purposes
AASHTO M140...........Standard Specification for Emulsified Asphalt

AASHTO M208...........Standard Specification for Cationic Emulsified Asphalt (ASTM D2397-
02)
AASHTO M320...........Standard Specification for Performance-Graded Asphalt Binder
AASHTO M332...........Standard Specification for Performance-Graded Asphalt Binder Using
Multiple Stress Creep Recovery (MSCR) Test, Single User Digital
Publication
AASHTO R28 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a
Pressurized Aging Vessel (PAV)
AASHTO R35 ............ Standard Practice for Superpave Volumetric Design for Hot-Mix Asphalt
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(HMA)
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AASHTO T44 .............Standard Method of Test for Solubility of Bituminous Materials
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AASHTO T48 .............Standard Method of Test for Flash and Fire Points by Cleveland Open
Cup
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AASHTO T240 ...........Standard Method of Test for Effect of Heat and Air on a Moving Film of
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Asphalt Binder (Rolling Thin-Film Oven Test)
AASHTO T313 ...........Standard Method of Test for Determining the Flexural Creep Stiffness
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of Asphalt Binder Using the Bending Beam Rheometer (BBR)
AASHTO T283 ........... Standard Method of Test for Resistance of Compacted Asphalt Mixtures
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to Moisture-Induced Damage
AASHTO T314 ...........Standard Method of Test for Determining the Fracture Properties of
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Asphalt Binder in Direct Tension (DT)

AASHTO T315 ...........Standard Method of Test for Determining the Rheological Properties of
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Asphalt Binder Using a Dynamic Shear Rheometer (DSR)

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AASHTO T316 ...........Standard Method of Test for Viscosity Determination of Asphalt Binder
Using Rotational Viscometer
AASHTO T350 ...........Standard Method of Test for Multiple Stress Creep Recovery (MSCR)
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Test of Asphalt Binder Using a Dynamic Shear Rheometer (DSR)

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AASHTO PP60 ........... Standard Practice for Preparation of Cylindrical Performance Test
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Specimens Using the Superpave Gyratory Compactor (SGC)

AASHTO PP61 .......... Standard Practice for Developing Dynamic Modulus Master Curves for
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Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester
(AMPT)
AASHTO TP79 .......... Standard Method of Test for Determining the Dynamic Modulus and
Flow Number for Hot Mix Asphalt (HMA) Using the Asphalt Mixture
Performance Tester (AMPT)
BS 812-110 ................Testing aggregates Methods for determination of aggregate crushing

value (ACV)
BS EN 12697-13 ........Bituminous mixtures. Test methods for hot mix asphalt. Temperature
measurement
5.1.3 Definitions
2 Base Course: One or more bituminous layers beneath Wearing Course and above the
unbound Road Base Layer. It usually consists of a mixture of aggregates and bituminous
materials and functions as a structural portion of pavement.
3 Wearing Course: Top surface bituminous course, which resists skidding, traffic abrasion, and
the disintegrating effects of climate.
5.1.4 Submittals
1 The Contractor shall submit for approval a proposed Job Mix Formula (JMF) together with all
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applicable design data at least one month before beginning the work. The JMF shall give a
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combined gradation showing a single definite percentage passing each sieve as well as a
percentage of each material to be used in the mix. The JMF shall also establish the mixing
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and compaction temperature values and a compaction reference density. The Engineer will
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test samples of the materials proposed for use in order to check their quality and to check the
proposed mix design. The Contractor shall report all the values obtained in the laboratory
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design and shall submit these together with a copy of the plotted curves resulting from the
tests in an approved form to the Engineer. The Engineer may require verification of the
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submitted design before giving approval. The Engineer shall approve the optimum binder
content based upon the design values submitted by the Contractor and shall notify the
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Contractor of the value. No asphalt works will be allowed to commence before the
Contractor receives written approval from the Engineer for his JMF.
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2 The asphalt mix design submission shall include a copy of valid calibration certificates from a
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calibration service agency approved by the Laboratories and Standardization Affairs (LSA) for
the batching plant and the relevant laboratory equipment such as but not limited to balances,
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proving rings, and load devices. Approval certificates for mix designs will not be issued if the
above requirements have not been complied with.
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3 Based on the Engineer request, the Contractor shall submit the pertinent certifications of
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materials, equipment, plants, personnel and processes in relation to the project. Certificates
must be issued by a competent authority approved by the Engineer.
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(a) Bituminous and asphalt materials production, storage, transportation, identification and
marking procedure and traceability to source of production.
(b) Quality assurance and quality control plans for laying, compaction and all construction
activities.
(c) Quality control testing plan.
(d) Equipment and its suitability to fulfil all construction activities to the required quality.
(e) Personnel capability.
(f) Safety and environment preservation measures.
5 The Contractor shall provide the Engineer with a complete report on the origin and
composition of all stone and/or gravel aggregates to be used in the work (Aggregate
Resources Report). All materials shall comply with the specified requirements for the various
aggregates.
6 Delivery of materials produced from commercial manufacturing process shall be

accompanied by the manufacturer’s certification and test reports from local approved
laboratory showing the materials compliance with the specification for which it is stipulated.
7 After receiving the approval of specific sources of material the Contractor cannot change
these sources without prior written approval of the Engineer.
1 The Contractor shall notify the Engineer of the sources of materials and the Engineer shall
approve the sources. All materials shall be tested and approved before use.
2 Where the quality of material from a source of material does not comply with the designated
requirements, the Contractor shall furnish material that does comply from other sources.
Delivery of materials produced from commercial manufacturing processes shall be
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accompanied by the manufacturer's certification and test report showing that the materials
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comply with the designated requirements.
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3 No change shall be permitted in the source of any of the materials until the technical
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submissions listed in the specification have been made and approved by the Engineer.
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All processed materials shall be tested and approved before being stored at the site or
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incorporated in the works and may be inspected and tested at any time during the progress
of their preparation and use. Questionable materials, pending laboratory testing subsequent
approval shall not be unloaded and incorporated with materials previously approved and
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accepted.
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5 It is the full responsibility of both the asphalt mixture producer and the Contractor to obtain a
certificate which proves that the asphalt binder complies with the specifications. Furthermore,
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both the asphalt mixture producer and the Contractor shall perform all the required tests in an
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approved private laboratory to make sure that the asphalt binder being purchased complies
with the specifications. The LSA will, at any time, take samples from the asphalt mixtures
producer’s plants and test them as part of its quality practice.
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5.2 MATERIALS
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5.2.1 Unacceptable Materials

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1 Materials that do not conform to the designated requirements shall be rejected and
immediately removed from the site of the works unless otherwise instructed by the Engineer.
No rejected material, the defects of which have been corrected, shall be used until approval
has been given by the Engineer.
2 Bituminous paving courses shall consist of coarse aggregate, fine aggregate, filler material,
and bitumen binder. Mixture of two different types of rocks, e.g. igneous and sedimentary
having different engineering properties shall not be permitted.
3 During execution of works, variations in the specific gravity of any individual fraction of
aggregates used in the asphalt mixes by more than 1% shall cause the Engineer to request
for evaluation of aggregates consistency and compliance and/or mix design validation.
5.2.2 Fine Aggregate
1 Fine aggregate is that portion of the mineral aggregate passing the 2.36mm ASTM sieve for
the Marshall mix design and passing the 4.75mm sieve for the Superpave mix design.
2 Fine aggregate shall consist of crushed hard durable rock and shall be of such gradation that
when combined with other aggregates in proper proportions, the resultant mixture will meet
the required gradation. Fine aggregate shall be non-plastic and chemically stable.
3 The source of natural fine aggregate is considered to be the crusher site at which it is
produced. Crushed fine aggregate shall be produced by crushing clean coarse aggregate
and shall not be thin, flaky or elongated. Sampling of fine aggregate shall be in accordance
with ASTM D75.
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4 Fine aggregate shall be clean and free from organic matter, clay, cemented particles and
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other extraneous or detrimental materials.
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5 Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
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Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.
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The Contractor shall ensure that the sources of all fine aggregates have been approved by
the Municipality concerned.
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7 The specifications of fine aggregates for asphalt mixtures are listed in Table 5.1.
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Table 5.1
Fine Aggregate Specifications for Marshall Mixes
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Parameter Standard Specification Limits Minimum Frequency

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4% max. (stockpile)
Plasticity index ASTM D 4318
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Non Plastic (hot bins)

Sand equivalent value ASTM D2419 45% min. - Each source
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Soundness by magnesium
ASTM C88 18% max. - Visible change in
sulphate
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material
Acid soluble chloride content BS 1377 Part 3 0.1% max.
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- 1 test every 2000m
Acid soluble sulphate content BS 1377 Part 3 0.5% max.
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Clay lumps and friable particles ASTM C142 None

Organic Impurities ASTM C40 No Impurities
5.2.3 Coarse Aggregate
1 Coarse aggregate is that portion of the mineral aggregate retained on the 2.36mm ASTM
sieve for the Marshall mix design and retained on the 4.75mm ASTM sieve for the
Superpave mix design. Coarse aggregate shall consist of crushed natural stones and gravel.
Crushed particles shall be cubic and angular in shape and shall not be thin, flaky or
elongated. The gradation shall be such that when combined with other aggregate fraction in
proper proportions, the resultant mixture will meet the required gradation.
2 The source of crushed aggregate is considered to be the crushing site from which it is
produced. Sampling of coarse aggregate shall be in accordance with ASTM D75.
3 Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and
other extraneous or detrimental material.
4 The specifications of coarse and combined aggregates for asphalt mixtures are listed in
Table 5.2.
5 Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.
6 If directed by the Engineer, the polished stone value (PSV) should be determined for wearing
course aggregates of main lane as per ASTM D3319. The PSV shall not be less than 45.
5.2.4 Recycled Aggregate
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1 Recycled aggregate produced from excavating natural ground can be used in asphalt
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mixtures for temporary roads and for roads, which serve agricultural areas provided that the
specifications stated in Section 6 - Part 9 are complied.
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Table 5.2
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Coarse and Combined Aggregate Specifications for Marshall Mixes
Parameter Standard nt
Base Course Base Course Wearing
Minimum
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Frequency
(Class A) (Class B) Course
One or more Fractured
ASTM D5821 100% min. 100% min. 100% min.
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Faces
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Two or more Fractured
ASTM D5821 85% min. 85% min. 85% min.
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Faces
Table 5.7, Job Mix gradation and Table
Gradation (Combined) ASTM C136 - Each source
5.10 tolerances
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Flat and Elongated - Visible change

ASTM D4791 15 % max. 15% max. 10 % max.
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Particles (5:1) in material

Soundness
ASTM C88 15 % max. 15% max. 10 % max. - 1 test every
(5 cycles by MgSO4) 3
2000m
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ASTM C131
Los Angeles Abrasion 30% max. 30% max. 25% max.
ASTM C535
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Water absorption ASTM C127 2.0% max. 2.0% max. 1.5% max.
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Aggregate Crushing BS 812

25 % max. 25 % max. 20% max.
Value (ACV) Part 110
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1
Higher values can be recommended by the engineer based on the design ESAL.
5.2.5 Mineral Filler
1 Mineral filler when separately supplied from an external source shall consist of finely ground
mineral matter in accordance with ASTM D242 such as rock dust, hydrated lime, cement or
other material which can satisfy the Engineer will produce asphalt mixes of at least equal
quality. It shall be free from organic substances and clay, shall be thoroughly dry and free
from agglomerations, shall be non-plastic and shall meet the grading requirements shown in
Table 5.3.
2 Hydrated lime shall conform to the definitions given in ASTM C51. Sampling, packaging and
marking of hydrated lime shall be in accordance with ASTM C50. Storage and use of the
hydrated lime shall at all times be such as to protect the material from the weather.
Table 5.3
ASTM Sieve % Mass Passing
600 µm 100
300 µm 95 - 100
150 µm 90 – 100
75 µm 70 – 100
3 The grading of mineral filler shall be carried out in accordance with ASTM D546.
4 When cement is used as mineral filler, it shall meet the requirements of ASTM C150.
5.2.6 Asphalt Binder
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1 The asphalt binder specified for use in the asphalt mixes shall be either of the following:
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(a) Penetration grade 60-70: This binder type shall be graded in accordance with ASTM
D946. The 60-70 binder specifications are listed in Table 5.4. Sampling shall be in
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accordance with ASTM D140. The 60-70 penetration graded binder is generally
equivalent to PG 64-10 performance graded binder.
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PG 76-10: Based on the Engineer approval, the PG76-10 binder can be used in
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asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting
AASHTO M320 and ASTM D6373 specifications in addition to separation test criteria
as listed in Table 5.5. Sampling shall be in accordance with ASTM D140.
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2 Prior to the commencement of the mix design, the Contractor shall provide a certificate
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indicating conformance of binder with the specifications stated above. This certificate shall be
obtained from an approved laboratory.
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3 The asphalt binder shall be prepared by the refining of petroleum and shall be uniform in
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character. Blending of asphalt binders from different refineries will be permitted only with the
written approval of the Engineer.
Table 5.4
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Specifications of Bitumen Penetration Grade 60 – 70

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60 – 70 Pen
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Min. Max.
Penetration (0.1 mm) at 25C - Each source
ASTM D5 60 70
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-100g, 5 Sec
Softening Point Ring & Ball
ASTM D36 46 - - 1 test per 75t of asphalt
Apparatus, C binder per layer
Flash Point, Cleveland Open
ASTM D92 230 -
Cup, C
Ductility at 25 C, cm ASTM D113 100 - - Each source
Solubility Trichloroethylene, % ASTM D2042 99 -
Loss on heating, % ASTM D6 - 0.2
Penetration of Residue of - 1 test per 450t of asphalt
ASTM D5 52 -
original after TFOT, % binder per layer
Ductility of Residue after
ASTM D113 50 -
TFOT at 25 C, 5cm/min, cm
Table 5.5
Specifications of Performance Graded Binders / Polymer Modified Binders (PMB)
Standard Minimum
Parameter Specification
AASHTO ASTM Frequency
Tests on Original Binder
Average 7 days maximum pavement
o - - < 76
design temperature, ( C)
Minimum pavement design - - - Each source
o >-10
temperature,( C)
o
- Visible change in
Flash Point Temperature, Minimum ( C) T48 D92 230 material
Rotational Viscosity, Maximum 3 Pa.s,
o T316 D4402 135 - 1 test per 450t of
Test Temperature ( C)
asphalt binder per
Dynamic Shear, G*/sinδ, Minimum, 1.00
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o T315 D7175 76 layer
kPa , Test Temperature ( C) at 10 rad/s
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Solubility, min, % T44 D5546 99
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1
Separation Test: Absolute Difference
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between G* @ 76 C and 10 rad/s of Top - D7173 20
and Bottom Specimens, Maximum, %
T240 D2872
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Requirements of the Rolling Thin Film Oven Residue ( T240 / D2872)
Mass Loss, Maximum, Percent 1
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Dynamic Shear, G*/sinδ, Minimum, 2.20
o T315 D7175 76
kPa , Test Temperature ( C) at 10 rad/s
- Each source
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Pressure Aging Vessel Residue (D6521 / R28)

PAV Aging Temperature , ( C)
o
R28 D6521 110 - Visible change in
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Dynamic Shear, G*.sinδ, Maximum 5000 material

o T315 D7175 37
kPa , Test Temperature ( C) at 10 rad/s - 1 test per 450t of
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Creep Stiffness, S, Maximum 300 MPa asphalt binder per

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and m-value, Minimum 0.300 at 60 T313 D6648 0 layer

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seconds , Test Temperature ( C)
2
Direct Tension , Failure Strain, Minimum,
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1.0% (loading rate of 1.0 mm/min),Test T314 D6723 0

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o
Temperature( C)
1
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Absolute Difference = Abs(100x(top-bottom)/top).

2
If the creep stiffness is below 300 MPa, the direct tension test is not required. If the creep stiffness is
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between 300 and 600 MPa, the direct tension failure strain requirement can be used in lieu of the creep
stiffness requirement. The m-value requirement must be satisfied both cases.
4 Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
AASHTO M332 and will be required to indicate elastic response in percent recovery when
tested in accordance with AASHTO T350 / ASTM D7405.
5 Binders modified using Crumb Rubber and other binders containing particulate materials,
which are graded according to AASHTO M320 and/or AASHTO M332, shall not include
particles with longest dimensions of more than 250μm. In addition, the requirements listed in
Table 5.5 shall be satisfied.
5.2.7 Prime Coat
1 Liquid asphalt for use as prime coat shall be MC-70 medium curing cutback asphalt in
accordance with ASTM D2027 or AASHTO M82.
2 The prime coat shall be a cutback consisting of a 60/70 penetration grade bitumen and
kerosene. The residue from the distillation test, carried out to 360 C in accordance with
ASTM D402, shall be a minimum of 55 % (by volume), as determined by the difference
method. Sampling shall be in accordance with ASTM D140. One sample shall be tested
every 5 tons.
5.2.8 Tack Coat
1 Emulsified asphalt for use as tack coat in asphalt works may be CSS 1h or CRS-2 cationic
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emulsified asphalt in accordance with AASHTO M 208 or SS 1h anionic emulsified asphalt in
in
accordance with ASTM D977 or AASHTO M140 unless otherwise designated.
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2 Emulsified asphalt shall be of the slow-setting cationic or anionic type of the CSS-1h or SS-
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1h grades respectively and shall conform to the designated requirements. Sampling shall be
in accordance with ASTM D140. One sample shall be tested every 5 tons.
5.2.9 Delivery, Storage and Handling

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1 Materials shall be so stored and handled as to assure the preservation of their quality and
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fitness for use. Materials, even though approved before storage or handling, may again be
inspected and tested before use in the Works.
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2 Stored material shall be located so as to facilitate their prompt inspection. All storage
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locations on land not owned by the Contractor shall be restored to their original condition at
the Contractor's expense.
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3 Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
or contamination of the various sizes and to prevent contamination of materials by dust.
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Stockpiles shall be kept flat and the formation of high cone-shaped piles shall not be
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permitted. When conveyor belts are used for stockpiling aggregates, the Engineer may
require the use of baffle-chutes or perforated chimneys.
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4 Where trucks are used to construct stockpiles, the stockpiles shall be constructed one layer
at a time with trucks depositing their loads as close to the previous load as possible. The use
of tractors or loaders to push material deposited at one location to another location in the
stockpile shall not be allowed during the construction of the stockpile, and their use shall be
limited to levelling the deposited material only.
5 Stockpiles of aggregate located at permanent asphalt plant sites shall be separated by bin
walls and shall be constructed on asphalt or concrete floors. Stockpile locations and
procedures at temporary asphalt plant sites shall be as approved by the Engineer.
6 Intermediate storage of hydrated lime and commercial mineral filler for equipment feeding the
asphalt plant shall be silos of adequate size to ensure a minimum of one day's continuous
operation.
5.2.10 Inspection and Control
1 For verification of weights and measures, character of materials and determination of

temperatures used in the preparation of the asphalt mixes, the Engineer shall at all times
have access to all portions of the mixing plant, aggregate plant, storage yards, crushers and
other facilities used for producing and processing the materials of construction.
2 The Engineer shall have authority to instruct sampling and testing of any material supplied to
the site from any source whatsoever in order to establish their compliance and to accept or
reject as he deems necessary. Samples shall also be taken from completed work to
determine compliance. The frequency of all sampling and testing shall be as designated.
3 The Contractor shall arrange for obtaining specimens of materials, asphalt mixes and
samples cut from the paving courses after compaction, including the provision of necessary
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equipment and plant for obtaining these specimens and samples. This work shall be
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performed in the presence of the Engineer. The Engineer shall take possession of the
samples upon their removal from the roadway unless the Contractor is authorised otherwise
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4 In particular, the Contractor shall provide a portable coring machine and bits for taking 150
mm diameter full depth cores of all bituminous paving courses. The coring machine shall be
available to the Engineer upon request.
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5 In addition to the foregoing, one set of three laboratory compacted specimens and one
uncompacted coated sample for each mix type and mixer plant for each day’s production,
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shall be delivered to LSA no later than 12 hours after compaction of the specimens together
with the mix type and project details.
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6 Upon the first erection of the batching plant and at least once every three months thereafter,
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the plant shall be calibrated by a calibration service organisation approved by the LSA.
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5.3 MARSHALL MIX DESIGN
5.3.1 General
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1 The types of bituminous paving mixes shall be as designated on the project drawings or in
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the contract documents.

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2 The LSA shall act as the engineer for the approval of asphalt mix designs and materials
submitted by the Contractor.
3 The contractor shall prepare the mix design with all necessary supporting documentation
which shall include the results of the Contractor’s own laboratory procedures.
4 The Contractor shall carry out a trial batching and trial laying of the particular mix design.
5 The testing and sampling of the mix design by the LSA will take place for both the laboratory
verification and the trial batching and laying.
6 Based on the results of the trial batching and laying the contractor may be required to make
amendments to the mix design. Providing the mix design conforms to the specification the
mix shall be approved by the LSA.
7 The LSA shall issue a certification for the job standard mix to the Contractor.
8 The approved Job Mix Formula may be amended as a result of experience in the execution
and performance of the permanent asphalt works. Such an amendment may be submitted by
the Contractor for the Engineer's approval in which case the Contractor shall submit full
details of the proposed amendment together with such data as is necessary to support his
submittal. Amendment may also be directed by the Engineer.
9 Approval by the Engineer of the Job Mix Formula or amendments thereto shall in no way
relieve the Contractor of his obligations under the Contract, and the Contractor shall be
responsible for the soundness of the asphalt paving mixes and the satisfactory execution and
performance of the asphalt paving courses.
5.3.2 Marshall Mix Design Criteria
1 The Asphalt Institute MS-2 “Mix Design Methods for Asphalt Concrete and Other Hot-Mix
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Types” shall be used in designing the bituminous mixtures using Marshall design method.
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2 The recommended compacted layer thicknesses are shown in Table 5.6.
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Table 5.6
Recommended Compacted Layer Thicknesses
Base Course Base Course nt Wearing
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(Class A) (Class B) Course(WC)
80 to 100 mm 60 to 80 mm 45 to 55 mm
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3 When tested according to ASTM C136, the combined mineral aggregate shall conform to
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Table 5.7 for asphalt concrete mixes.

Table 5.7
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Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes

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Percentage Passing (By Weight)

ASTM Sieve Size
Base Course Base Course
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Wearing Course
(Class A) (Class B)
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37.5 mm 100 - -
25.0 mm 80 - 100 100 100
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19.0 mm 62 - 92 80 - 100 86-100

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12.5 mm - 63 - 85 69 - 87
9.5 mm 45 - 75 57 - 77 58 - 78
4.75 mm 30 - 55 40 - 60 40 - 60
2.36 mm 20 - 40 25 - 45 25 - 45
0.850 mm 15 - 30 15 - 30 15 - 30
0.425 mm 10 - 22- 10 - 22 10 - 22
0.180 mm 6 - 15 6 - 15 6 - 15
0.075 mm 2-8 2-8 2-8
4 The "Laboratory Designed Mixture" for all types of bituminous coated courses shall comply
with the requirements given in Table 5.8. Note that any deviation from these requirements
shall be approved by LSA.
Table 5.8
Design Criteria for Marshall Design Mixes
Base Course Base Course
Parameter Wearing Course
(Class A) (Class B)
Aggregate Properties Tables 5.1 and 5.2
Aggregate Grading Table 5.7
Number of Compaction blows at each
75 75 75
end of specimen (see paragraph 5)
Binder Content (% of total mix)
3.2 – 4.4 3.4 – 4.4 3.4 – 4.4
inclusive of tolerances
Stability minimum (kN) 9.5 min. 9.5 min. 11.5 min.
Flow (mm) 2 to 4 2 to 4 2 to 4
Marshall Quotient (Stability/Flow)
g
4.75 min. 4.75 min. 4.75 min.
(kN/mm)
in
Voids in Mix (Air Voids) (%) 4 to 8 4.5 to 8 5 to 8
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Voids in Mineral Aggregate VMA (%) Table No.5.9
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Voids Filled with Asphalt VFA (%) 50 to 70 50 to 75 50 to 75
Voids in Marshall Specimen at 400
Blows per face at optimum binder
content (%)
3.2 min. nt 3.4 min. 4.0 min.
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Retained Stability (%) 75 min. 75 min. 75 min.
(Filler/Binder) Ratio 0.8 to 1.5 0.8 to 1.5 0.75 to 1.35
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Note: Relevant ASTM standards shall be used for testing.

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5 Base Course (Class B) and Wearing Course samples shall be prepared and tested using
Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while
Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
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D5581. However, based on the Engineer approval, samples having aggregate sizes larger
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than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
next lower grading sizes.
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6 Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
ASTM D6931 shall be obtained for the mix for quality control purposes. The TSR acceptance
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limits shall be determined at mix design stage and approved by the Engineer.
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Table 5.9
Minimum Percent Voids in Mineral Aggregate (VMA)
Minimum VMA, Percent
Nominal Maximum 3
1, 2
Particle Size (mm) Design Air Voids, Percent
3.0 4.0 5.0
1.18 21.5 22.5 23.5
2.36 19.0 20.0 21.0
4.75 16.0 17.0 18.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0
50 9.5 10.5 11.5
63 9.0 10.0 11.0
1
Standard Specification for Wire Cloth Sieves for Testing Purposes, ASTM E11 (AASHTO M92).
2
The nominal maximum particle size larger than the first sieve to retain more than 10 percent.
3
Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between
those listed.
7 After the Job Mix Formula has been established and approved, all mixes furnished shall
conform thereto within the following tolerances:
Table 5.10
Job Mix Tolerances For Field Mixtures
Base Course Base Course Wearing
(Class A) (Class B) Courses
Description
Aggregate retained on 4.75mm sieve
 5%  4%  4%
or larger
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Aggregate passing 4.75mm sieve
 4%  3%  3%
and retained on 850m sieve
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Aggregate passing 850m sieve and
 3%  2%  2%
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retained on 75m sieve
Aggregate passing 75m sieve  1.5%

nt  1.0%  1.0%
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Binder Content  0.3%  0.2%  0.2%
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8 The ‘Job Standard Mix Density’ shall be obtained by making six standard Marshall specimens
from samples of the approved ‘Job Standard Mixture’ determining the bulk specific gravity of
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each and comparing them with the mean value of the six. Any individual result which differs
from the mean by more than 0.015 shall be rejected, and provided that not more than two
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results are so rejected the mean of the remaining result shall be designated the ‘Job
Standard Mixture Density’. The absolute density shall be considered as the theoretical
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specific gravity calculated in accordance with ASTM D2041.
5.3.3 Quality Control Testing

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1 The Contractor shall submit a testing plan to the Engineer for approval that demonstrates
how he shall prove compliance with the requirements for compaction, mix composition, level,
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evenness and all other requirements of Section 6. Each lot shall be approved by the
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Engineer before placing any subsequent asphalt concrete course. In cases where the asphalt
course is laid in more than one layer, each layer shall be tested and approved before placing
the subsequent asphalt concrete layer.
2 In addition to the following requirements one set of three laboratory-compacted specimens

and one uncompacted coated sample for each mix type and mixer plant for each day’s
production shall be delivered to the LSA no later than 12 h after compaction of the
specimens. Details of compaction date, time and temperature of mix shall be provided with
the specimens together with mix type and project details.
3 The Contractor shall cut samples from each completed asphalt course during the progress of
the work and before final acceptance as directed by the Engineer. The Engineer shall
determine the location of the samples.
4 When testing for compaction at joints the edge of the core shall not be more than 50 mm or
less than 25 mm from the joint.
5 Compacted samples shall be taken by coring in accordance with ASTM D5361, for testing by
an approved laboratory. The core diameter shall be 150 mm. where the Contractor fails to
provide cores as required by the Engineer, the Engineer may arrange for the taking of cores
on behalf of the Contractor at his cost. Samples shall be taken of the asphalt mix for the full
depth of the course. A sample shall comprise a pair of adjacent cores and the average
density of these shall be the density of the sample.
6 Whenever deficiencies are noted in loose mix samples or core samples, the Engineer may
direct the taking of additional cores at the Contractor's expense in order to define the area of
pavement involved.
7 Hot asphalt mix of the same type shall be placed and compacted in holes left by sampling.
The mixture shall be compacted to the percentage compaction required for the layer using a
vibrating hammer.
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8 Quality control testing of the asphalt mixtures during construction shall follow the frequencies
shown in Table 5.12 for Marshall Mixtures:
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9 Base Course (Class B) and Wearing Course samples shall be prepared and tested using
Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while
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Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
D5581. However, based on the Engineer approval, samples having aggregate sizes larger
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than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
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next lower grading sizes.

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10 Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
ASTM D6931 shall be tested for quality control purposes. The TSR acceptance limits shall be
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based on the mix design obtained limits approved by the Engineer.

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11 If it appears from the analysis of samples of loose mix or cores that the asphalt content or
aggregate gradation are beyond the permissible tolerances specified for the Job Mix Formula
(established for each respective asphalt course mix) and that, such variation affects the
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characteristics of the asphalt mix conformity to the designated requirements is concerned,

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this shall be considered a major defect in the work. The portion of the asphalt course
represented by these samples shall be rejected.
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12 The density of the compacted mixes shall be related to the daily Marshall density determined
by making minimum four Marshall specimens from samples collected from behind the paver.
The density of each sample shall be determined and compared with the mean value. Any
3
individual result, which varies from the mean by more than 0.015gm/cm shall be rejected.
The daily Marshall density shall not differ from the Job Mix Design Density by more than
1.0%.
13 The field density, as determined from each core sample and related to the daily Marshall
Density, obtained as shown above, shall be as follows:
Table 5.11
Layer Relative Density (%)

Base Course 97 – 101.8
Wearing Course 98 – 101.8
14 The finished road surface shall be inspected visually techniques and if directed by the
Engineer the structural ability of the pavement in terms of layer modulus shall be assessed
by using the Falling Weight Deflectometer (FWD) and Light weight Deflectometer (LWD).
15 For safety purposes the pavement surface friction shall be measured by the pendulum
portable tester or locked wheel tester in accordance with ASTM E303.
Table 5.12
Quality Control Testing of the Marshall Mixtures
Item / Parameter Standard Specification Limits Minimum Frequency
Aggregate conformance Sections 5.2.1, 5.2.2 and 5.2.3

Mineral Filler conformance Section 5.2.5 Every 300t
g
Prime Coat conformance Section 5.2.7
in
Tack Coat conformance Section 5.2.8
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Asphalt Binder conformance Section 5.2.6
2
0.45 – 0.75 kg/m
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2
Rate of application for Prime Coat ASTM D2995 - 1 per 250 m
at 60 – 85 C
2 - 1 every 75m per
Rate of application for Tack Coat ASTM D2995
nt
0.15 – 0.38 kg/m
at 10 – 60 C
lane
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Sampling of bituminous mixtures ASTM D979 - Test based
 10 C of JMF
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temperature in truck
BS EN 12697
 135 C min. at paver
1
Temperature of bituminous mixture Each truck
Part 13
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 120 C min. prior

rolling
2
1.0% of Job
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ASTM D2726
Daily Bulk density (See paragraph 12) 3 Daily
ASTM D1188 Standard Density
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Table 5.7, Job Mix

ASTM D5444
Gradation of extracted aggregates gradation and Table
ASTM C117
5.10 tolerances
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ASTM D2172 Job Mix value with

Binder content
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ASTM D6307 Table 5.10 tolerances

Marshall Stability, Flow and ASTM D6927 - Each source
Table 5.8
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4
Stability/Flow Ratio ASTM D5581 - Visible change in
ASTM C127 material
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Voids in mineral aggregate (VMA) Table 5.9 - 1 test per 300t per
ASTM C128
ASTM D2726
2 layer for Base
Voids filled with asphalt (VFA) 3 Course
ASTM D1188
- 1 test per 150t per
Voids in Mix (Air Voids) (%) layer for Wearing
ASTM D2041
Voids in Marshall Specimen at 400 ASTM D2726
2 Course
3 Table 5.8
Blows per face at optimum binder ASTM D1188
content (%)
ASTM D2172
(Filler/Binder) Ratio ASTM D6307
ASTM C136
- 1 test per 600t per
layer for Base
ASTM D2041
2 Course
In-place air voids ASTM D2726 5 – 8%
3 - 1 test per 300t per
ASTM D1188
layer for Wearing
Course
Item / Parameter Standard Specification Limits Minimum Frequency

ASTM D6927 1 test per 3000t per
Retained Stability (%) (Paragraph 16) 4 75 min.
ASTM D5581 layer
5 At 50m intervals in
Field density (nuclear gauge) ASTM D2950 Table 5.11
alternate wheel tracks
ASTM D5361 - 1 test per 200t per
5 2
Field density (2 cores) ASTM D2726 Table 5.11 layer for Base Course
3
ASTM D5361 layer for Wearing
Thickness Section 5.11.1 Course
ASTM D3549
Evenness of surface Section 5.11.2 & 5.11.3
1
As per polymer manufacturer recommendation and mix design for polymer modified binders
2
If water absorption ≤ 2%
g
3
If water absorption > 2%
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4
For samples containing more than 25mm size aggregates
5
For acceptance of in-situ compaction
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16 The Retained Stability is the percentage of the average stability of 3 samples conditioned for
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24 hours at 60  1C water bath and the average stability of 3 samples conditioned for 4
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hours in 60  1C air bath. These two sets of samples shall be prepared at the optimum
binder content by applying 75 blows and kept at ambient temperature for 17 – 20 hours and
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shall have similar average densities.
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17 Each day the produced mixes shall be tested for checking their compliance with the approved
Job Standard Mix criteria. When unsatisfactory results or changed conditions make it
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necessary, a new job-standard following approval of new mix design shall be established.
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5.4 DENSE BITUMEN MACADAM

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1 The mix properties for Dense Bitumen Macadam are listed in Table 5.13.
Table 5.13
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Properties of Mix for Dense Bitumen Macadam

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Parameter Base Wearing

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Course Course
Number of Compaction blows at each end of specimen 75 75
Binder Content (% of total mix) inclusive of tolerances 3.2 – 4.0 3.5 – 4.1
Stability minimum (kN) 7.5 10.0
Flow (mm) 2-4 2–4
Marshall Quotient (Stability/Flow) (kN/mm), min 3.7 4.9
Voids in Mix (Air Voids) (%) 7 - 11 6–9
Voids in Mineral Aggregate VMA (%) 14 - 20 14 - 20
Voids Filled with Asphalt VFA (%) 47 - 60 48 - 60
Retained stability 75 min. 75 min.
2 When tested according to ASTM C136, the combined mineral aggregate shall conform to
Tables 5.14, 5.15 and 5.16.
Table 5.14
Aggregate Gradation for Dense Bitumen Macadam Road Base (Unbound)
B.S Sieve Aggregate, Crushed Rock or Gravel
(mm) Percentage by mass passing
50.0 mm 100
37.5 mm 95 - 100
28.0 mm 70 - 94
14.0 mm 56 - 76
6.3 mm 44 - 60
3.35 mm 32 - 46
0.300 mm 7 - 21
0.075 mm 2- 8
g
Table 5.15
in
Aggregate Gradation for Dense Bitumen Macadam Asphalt Base Course
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Aggregate, Crushed Rock or Gravel
B.S Sieve
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(mm) Percentage by Mass Passing for Finished Thickness of Base Course
80 - 100 mm 70 - 90 mm 50 - 70 mm
50.0 100
nt
- -
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37.5 95 - 100 100 -
28.0 70 - 94 95 - 100 100
20.0 - 71 - 95 95 - 100
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14.0 56 - 76 58 - 82 65 - 85
10.0 - - 52 - 72
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6.3 44 - 60 44 - 60 39 - 55
3.35 32 - 46 32 - 46 32 - 46
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0.300 7 - 21 7 - 21 7 - 21
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0.075 2 - 8 2 - 8 2 - 8
Table 5.16
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Aggregate Gradation for Dense Bitumen Macadam Asphalt Wearing Course

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Aggregate, Crushed Rock or Gravel

B.S Sieve
Percentage by Mass Passing for Finished Thickness of Wearing Course
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(mm)
50 - 60 mm 40 - 50 mm 30 - 40 mm
28.0 100 - -
20.0 95 - 100 100 -
14.0 70 - 90 95 - 100 100
10.0 55 - 75 70 - 90 95 - 100
6.3 40 - 60 45 - 65 55 - 75
3.35 25 - 40 30 - 45 30 - 45
1.18 15 - 30 15 - 30 15 - 30
0.075 2 - 6 2 - 6 2 - 6
5.5 SUPERPAVE MIX DESIGN
1 Based on the Engineer approval, the Superpave Mix Design Method can be used to design
the asphalt mixtures for Wearing Course and Base Course layers. The design of the
Superpave asphalt mixtures shall follow the method outlined in AASHTO R35 and SP-2
“Asphalt Institute Superpave Mix Design Method” in liaison with LSA.
2 The contractor shall prepare the mix design with all necessary supporting documentation
which shall include materials production and handling specifications, plant quality procedures,
construction quality control and quality assurance procedures, quality control tests, mix
acceptance criteria and performance evaluation testing program. All documentations shall be
submitted to LSA for review and approval.
3 Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This
g
binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM
in
D6373 specifications and the criteria listed in Table 5.5.
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4 Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
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heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
AASHTO M332 and will be required to indicate elastic response in percent recovery when
tested in accordance with AASHTO T350. nt
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5 Based on the Engineer approval, the guidelines shown in the Appendix can be used for the
mix design. Note that software (ePAVE3) shall be validated prior use.
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6 The recent editions of the references shown in the Appendix are recommended to be used
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for preparation of mix design and quality control schemes.

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7 Table 5.17 can be used as a guide for sampling and testing frequency for quality control of
Superpave mixtures.
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8 Performance tests shown in Table 5.18 can be used to evaluate performance of Superpave
asphalt concrete mixtures.
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9 Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
Engineer for approval, detailed information for each mix which he proposes to furnish. The
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information shall include, but not be limited to the following:

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(a) Copy of mix certificate approval obtained from LSA and the mix design report.
(b) The source(s) of the aggregate for each mix as well as the pertinent test data and a
written certification that the aggregates conform to all of the quality requirements.
(c) Type of Asphalt modifier intended to be used in the project along with the Certificate of
Conformity of the modified asphalt binder to the required grade according to the
Superpave Performance Based Grading System.
(d) Pertinent test data on the type and properties of the aggregates, asphalt binder,
modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be
furnished.
(e) The type and location of plant to be used for mixing each mix.
(f) Any other support data and information special to the project (e.g. technical data
sheets of a polymer in case it was used).
Table 5.17
Sampling and Testing Frequency of Superpave Field Mixtures
Item / Parameter Standard Specification Minimum Frequency
Aggregate Conformance Sections 5.2.1, 5.2.2, 5.2.3 and Table 6 - Appendix
Mineral Filler conformance Section 5.2.5 Every 300t
Prime Coat conformance Section 5.2.7
Tack Coat conformance Section 5.2.8
Asphalt Binder conformance Section 5.2.6
2
0.45 – 0.75 kg/m 2
Rate of application for Prime Coat ASTM D2995 - 1 per 250 m
at 60 – 85 C
2 - 1 every 75m per
0.15 – 0.38 kg/m
Rate of application for Tack Coat ASTM D2995 lane
at 10 – 60 C
Sampling of bituminous mixtures ASTM D979 - Test based
 ±10 C of JMF
temperature in truck
g
 Min. JMF compaction
in
Temperature of bituminous mixture
BS EN 12697 temperature +20 C at Each truck
Part 13 paver
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 Min. JMF compaction
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temperature prior rolling
(sec. 1.5.4 – Appendix)
Binder content (%)
ASTM D2172
ASTM D6307 nt JMF value ±0.40
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Table 9
Gradation of extracted aggregates ASTM D5444
Appendix
Effective Specific Gravity of ASTM D6857
&
Gsb < Gse < Gsa - Each source;

Aggregates (Gse) ASTM D2041
- Visible change in
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Voids in mineral aggregate (VMA) AASHTO T312 ±1.5 material

Voids in Mix (Va) ASTM D6857 or - 1 test per 500t per
ASTM D2041 ±1.3 layer for Base
(Min 2 Gyratory specimens at Ndes)
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Density (% of Gmm) at Nmax (Eq. 2) Table 5 Course

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(Min 1 Gyratory specimens at Nmax) Appendix

ASTM D6857 / layer for Wearing
ASTM D2041 Course
Table 5
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Dust to binder ratio (P0.075 / Pbe) ASTM D2172 /

Appendix
ASTM D6307
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ASTM D5444
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Indirect tensile strength (IDT) ASTM D6931 IDT of JMF min.

ASTM D6931
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Sec. 1.5.8
Moisture Sensitivity (Retained IDT) Sec. 1.5.8 Weekly
Appendix
Appendix
Dynamic Modulus at 10 Hz, 45 C,
AASHTO PP60 Min. 1920 MPa
0kPa confinement
AASHTO TP79
Flow Number (Fn) at 54.4 C, 600kPa Procedures A, B Every 10,000t
deviatory stress, and 0kPa AASHTO PP61 Min. 740
confinement
In-place air voids 6 – 8%
ASTM D2726 layer for Base
Course;
Thickness Section 5.11.1
ASTM D3549 layer for Wearing
Course
At 50m intervals in
Field density (nuclear gauge) (%Gmm) ASTM D2950 92 – 94% alternate wheel
tracks
Evenness of surface Section 5.11.2 & 5.11.3
5.6 PERFORMANCE EVALUATION OF ASPHALT CONCRETE
1 Based on the Engineer request, the asphalt mixture performance properties can be
determined.
2 The performance properties of asphalt mixtures shall be measured for every asphalt
concrete layer at least on the following frequencies:
(a) Prior asphalt laying on a laboratory prepared sample at the asphalt binder content
specified in the JMF.
(b) Asphalt mix sampled from behind the paver every 10000t of mix.
3 The purpose of the performance testing is to allow for pavement performance evaluation and
verification of pavement structural design through the AASHTO Mechanistic-Empirical
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Pavement Design Guide. Performance models, references, test conditions are shown in table
in
5.18 below:
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Table 5.18
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Performance Models Criteria
Performance Test
Test Conditionsnt Applications / Use
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Model Reference
100X150mm cylindrical
The E* is used in mechanistic
AASHTO PP60, sample under uniaxial
&
Dynamic Modulus analysis to evaluate the structural

TP79 Procedure stress, zero confining
Master Curve responses of the asphalt
A, & PP61 pressure and sinusoidal
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concrete layers
deviator stress
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AASHTO PP60 100X150mm cylindrical To evaluate the rutting

characteristics of the asphalt
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Rutting Model & TP79 sample under triaxial

Procedure B stress mixture in the form of a rutting
model or Flow Number (FN)
a
64x50x380mm beam The initial flexural stiffness is

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specimen is subjected to measured at the 50th load cycle.

a 4-point bending with Fatigue life or failure shall be
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Fatigue Model AASHTO T321 free rotation and defined as the number of cycles
horizontal translation at corresponding to 50% reduction
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all load and reaction in the initial stiffness.

points
Conduct asphalt binder Viscosity-temperature relationship
A-VTS test in the (A-VTS) of the asphalt binder is
Rheometer (DSR) to determined in order to assess the
Aging Model ASTM D7175 measure G* and  in impact of binder aging on the E*
accordance with ASTM property of the asphalt mix at
D7175 at multiple various stages of the pavement
temperatures life
4 Modelling methods adopted by Asphalt Institute and Shell or equivalent shall be used. The
contractor shall submit a proposal includes performance modelling testing and interpretation
procedures to the Engineer for approval.
5.7 DELIVERY, SPREADING AND FINISHING
5.7.1 Delivery of Mixes
1 Sufficient plant capacity, haul vehicles and storage shall be provided so that adequate
supplies of mixture are delivered to site to ensure that continuous paving can be achieved.
2 The dispatching of the hauling vehicles to the job site shall be so scheduled that all material
delivered may be placed in daylight, unless the Engineer has approved the use of artificial
light. Delivery of material shall be at a uniform rate and in an amount well within the capacity
of the paving and compacting equipment.
3 All precautions shall be taken to protect the mix from the weather during transit and while
waiting to discharge.
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4 Hauling vehicles shall not be permitted to carry out tight turns on the laying surface.
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5 The mixture at delivery to the paver shall be within 10 C of the Job Mix Formula temperature
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and above an absolute minimum temperature of 135 C. Material which has fallen below the
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minimum temperature of 135 C before discharge shall be rejected and immediately removed
from site. Delivery temperature shall not exceed the maximum temperature specified for
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mixing at the plant
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6 Should a significant proportion of the mixture delivered to the paver fail to meet this
requirement, or should cold lumps be found in the mixture, the Engineer shall order that
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paving operations be suspended until measures are taken, to the approval of the Engineer, to
ensure compliance.
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5.7.2 Spreading and Finishing

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1 The Contractor shall prepare a paving plan and obtain approval of the Engineer to ensure
adequate equipment and paving sequences.
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2 Based on the approved paving plan and prior to the commencement of delivery of the mix the
Contractor shall erect and maintain an approved reference guide wire for controlling the
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levels of the laid mix. The reference guide wire shall be supported at intervals of not more
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than 5m.
3 The mix shall be laid upon an approved surface and only when weather conditions are
suitable and as designated. Upon arrival at the point of use, the asphalt mix shall be spread
and struck off to the grade, elevation and cross-section shape intended, either over the entire
width or over such partial width as may be required. If the material does not conform to the
requirements, it shall not be used and shall be discarded.
4 The laid material shall be compacted as soon as rolling can be effected without causing
undue displacement and while the temperature does not fall below 120 C for unmodified
asphalt mixes. Materials still uncompacted and below this temperature shall be rejected.
5 The compaction temperature for the laid polymer-modified asphalt binder mixes shall be
selected based on one of the following:
(a) As specified in the JMF.
(b) As established from the trial section.
6 The Contractor shall supply accurate calibrated thermometers suitable for measuring the
inner and surface temperature of the material. The material temperature shall be checked
immediately before rolling and at least every 30 minutes thereafter during forward progress.
A record of these temperatures shall be passed to the Engineer at the end of each day’s
work.
7 While paving is in progress, the output of the batching plant shall be exclusively reserved for
the operations and no mixture shall be supplied to other sites or projects.
8 If during laying, the paver is repeatedly delayed because of lack of mixture or if the paver
stands at one location for more than thirty minutes (for any reason), a transverse joint shall
be constructed. Paving shall not recommence until the Engineer is satisfied that paving will
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proceed uninterrupted and until at least four loaded vehicles have arrived at the paving site.
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9 The asphalt course shall be constructed to proposed levels and shall be homogeneous,
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providing after compaction an even surface free from undulations, rises or depressions and
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within the tolerances stipulated.
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In no case shall construction of a new asphalt concrete course begin until the previously laid
course has been tested and approved.
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11 When the same asphalt course is to be laid in more than one layer the second layer shall be
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placed as soon as practicable after the first layer has been finished, rolled and cooled, and
the Engineer may at his discretion request cleaning of the first layer and the application of a
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tack coat thereon if he so deems necessary.

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12 Transverse joints in succeeding layers shall be offset at least 2 m. Longitudinal joints shall
be offset at least 300 mm.
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13 The use of motor grader or hand spreading of the asphalt mix shall not be permitted except
in places where it is impractical to use pavers and shall be only with the specific permission
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of the Engineer. The asphalt mix shall comply with all conditions regarding trueness of level,
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thickness, and homogeneity of the mix.

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14 Automatic electronic screed controls shall be required on all pavers and shall be used with a
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9 m long articulated averaging beam or grade wire control as approved by the Engineer.
5.7.3 Compaction of Mixes
1 At least three rollers shall be required at all times, one self-propelled pneumatic-tire and two
self-propelled steel-wheeled. As many additional rollers shall be used by the Contractor as
necessary to provide specified asphalt course density and surface characteristics in an
orderly, efficient and continuous manner.
2 Before beginning construction of the permanent works, unless otherwise agreed with the
Engineer, the Contractor shall carry out compaction trials for each type and thickness of
asphalt course to establish an approved compaction procedure which shall then be used as a
minimum requirement for the compaction of the permanent works unless otherwise directed
or agreed by the Engineer.
3 The compaction trials shall involve all procedures specified for the permanent works
including testing as specified for the asphalt course under consideration and any equipment,
processes or procedures proposed by the Contractor which are not designated. Construction
of the permanent works shall not commence until a compaction procedure has been
approved in writing by the Engineer. Such approval shall in no way relieve the Contractor of
his responsibilities and obligations stipulated in the Contract.
4 Immediately after the asphalt mix has been spread and struck off, the surface shall be
checked and any irregularities adjusted and then compacted thoroughly and uniformly by
rolling.
5 To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly
moistened but excess water shall not be permitted.
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6 After the longitudinal joints and edges have been compacted, rolling shall start longitudinally
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at the sides of the road and shall gradually progress towards the centre. On super elevated
sections, rolling shall begin on the low side and progress to the high side, overlapping on
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successive trips by at least one-half the width of tandem rollers and uniformly lapping each
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proceeding track. The rollers shall move at a slow but uniform speed with the drive wheels
nearest the paver. The speed shall not exceed 4-5 km/h for steel-wheeled rollers or 8 km/h
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for Pneumatic-tire rollers. The operating speed shall be approved by the Engineer.
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7 The line of rolling shall not be changed suddenly or the direction of rolling reversed suddenly.
If rolling causes displacement of the material, the affected areas shall be loosened at once
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with hand tools and restored to the original grade of the loose material before being rerolled.
Heavy equipment or rollers shall not be permitted to stand on the finished surface before it
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has been compacted and has thoroughly cooled.

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8 When paving in a single width, the first lane placed shall be rolled in the following order:
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(a) Transverse joints.

(b) Longitudinal joints.
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(c) Outside edge.

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(d) Initial or breakdown rolling, beginning on the low side and progressing towards the high
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side.
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(e) Intermediate rolling.

(f) Final rolling.
1 When paving in echelon, 50 mm to 100 mm of the edge which the second paver is following
shall be left unrolled. When paving in echelon the edges between the first and the second
paver shall not be exposed more than 15 minutes nor 50m by distance without being rolled.
Particular attention shall be given to the construction of the transverse and longitudinal joints
in all courses.
5.7.4 Transverse Joints
1 Transverse joints shall be carefully constructed and thoroughly compacted to provide a

smooth riding surface. Joints shall be checked with a straightedge to assure smoothness and
true alignment. Joints shall be formed with a bulkhead, such as a board, to provide a straight
line and vertical face.
2 If the joint has been distorted by traffic or by other means, it shall be trimmed to line and the
face shall be painted with thin coating of emulsified asphalt before the fresh material is
placed against it. To obtain thorough compaction of these joints the material placed against
the joint shall be tightly pushed against the vertical face with a steel-wheeled roller.
3 The roller shall be placed on the previously compacted material transversely so that not more
than 150 mm of the rear rolling wheel rides on the edge of the joint. The roller shall be
operated to pinch and press the mix into place at the transverse joint. The roller shall
continue to roll along this line, shifting its position gradually across the joint, in 150 to 200 mm
increments, until the joint has been rolled with the entire width of the roller wheel. Rolling
shall be continued until a thoroughly compacted, neat joint is obtained.
5.7.5 Longitudinal Joints
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1 Longitudinal joints shall be rolled directly behind the paving operations. The first lane placed
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shall be true to line and grade and have a vertical face. The material being placed in the
abutting lane shall then be tightly pushed against the face of the previously placed lane.
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Rolling shall be done with a steel-wheeled roller.
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2 The roller shall be shifted over onto the previously placed lane so that not more than 150 mm
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of the roller wheel rides on the edges of the newly laid lane. The rollers shall then be
operated to pinch and press the fine material gradually across the joint. Rolling shall be
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continued until a thoroughly compacted, neat joint is obtained.
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3 When the abutting lane is not placed in the same day, or the joint is distorted during the day's
work by traffic or by other means, the edge of the lane shall be carefully trimmed to line,
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cleaned and painted with a thin coating of emulsified asphalt before the adjacent lane is
placed.
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4 The longitudinal joints in the surface course shall be along the same line as the traffic lane
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markers.
5.7.6 Paving Edges

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1 The edges of the asphalt course shall be rolled concurrently with or immediately after rolling
the longitudinal joint.
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2 Care shall be exercised in consolidating the course along the entire length of the edges.
Before it is compacted, the material along the unsupported edges shall be slightly elevated
with hand tools. This will permit the full weight of the roller wheel to bear on the material to
the extreme edges of the mat.
5.7.7 Breakdown Rolling
1 Breakdown rolling shall immediately follow the rolling of the longitudinal joints and edges.
Rollers shall be operated as close to the paver as possible to obtain adequate density without
causing undue displacement. In no case shall the mix temperature be allowed to drop below
120 C before breakdown rolling.
2 If the breakdown roller is steel wheeled, it shall be operated with the drive wheel nearest the
finishing machine. Pneumatic-tire rollers may be used as breakdown rollers.
5.7.8 Intermediate Rolling
1 Pneumatic-tire rollers or Steel wheeled rollers shall be used for the intermediate rolling.
2 The intermediate rolling shall follow the breakdown rolling as closely as possible and while
the paving mix is still hot. Rollers shall be used continuously after the initial rolling until all of
the mix placed has been thoroughly compacted. Turning of rollers on the hot paving mix
which causes undue displacement shall not be permitted.
5.7.9 Finish Rolling
1 The finish rolling shall be performed with three-axle tandem rollers unless otherwise
permitted by the Engineer. Finish rolling shall be accomplished while the material is still warm
enough for the removal of roller marks.
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2 All rolling operations shall be conducted in close sequence.
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3 In places inaccessible for the operation of standard rollers as specified, compaction shall be
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performed by manual or mechanical tampers of such design as to give the desired density.
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After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
and any irregularity of the surface exceeding the specified limits and any areas defective in
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texture, density or composition shall be corrected as directed by the Engineer, including
removal and replacement as directed by the Engineer.
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5.7.10 Protection of Laid Courses

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1 Sections of the newly finished work shall be protected from traffic of any kind until the mix
has been properly compacted and cooled. In no case shall traffic be permitted less than 24 h
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after completion of the asphalt course unless a shorter period is authorised by the Engineer.
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5.8 COLD PLANING

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1 The cold planing plant shall be to the approval of the Engineer.

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2 Cold planing plant shall have sufficient power, traction and stability to maintain the required
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depth of cut and slope. The control of the depth of cut and the slope shall be by an automatic
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system based on reference wires.
3 Cold planing shall be carried out to straight crossfalls to the designated thickness. Planing
shall be to a tolerance of  5 mm of the designated amount. The average thickness of
planing achieved shall be at least the thickness designated.
4 In areas where there is severe deformation of the existing pavement, it may be necessary to
vary the depth of planing.
5 Existing kerbs, gullies, manholes and other features shall not be disturbed by the planing
process. This may require the use of smaller plant or removal by hand tools.
6 Any joints at the edge of planed areas shall be cut vertically and straight using asphalt saws.
7 Cold planing shall be carried out in a longitudinal direction.

8 After planing the prepared surface shall be thoroughly brushed and suction swept by
mechanical means to the satisfaction of the Engineer. The surface shall be free from
gouges, ridges, continuous grooves and shall have a reasonably uniform finish.
9 Cold planing shall be performed so that at the end of a day’s work the termination line does
not present a hazard to traffic that may use the road.
10 Any cracks noted in the pavement shall be blown clean with compressed air. The Engineer
will inspect the planed surface and may instruct that further work is carried out for treating
cracks in the pavement.
5.9 PRIME COAT
5.9.1 General
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1 The work shall consist of furnishing and applying liquid asphalt and blotter material, if
required, to a previously prepared and approved subgrade or granular base/sub-base course
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as designated and to the full designated width.
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2 Prime coat shall not be applied when the ambient temperature is less than 13 C nor during
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rain, fog, dust storms or other unsuitable weather.
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5.9.2 Equipment Required
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1 The equipment used by the Contractor shall include a liquid asphalt distributor as described
in clause 5.17.3.
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2 If the surface is covered in wind-blown dust or fine aggregate then a power broom shall be
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provided. The power broom shall be self-propelled and equipped with a cylindrical, rotating
nylon bristle brush of not less than 760 mm in diameter and not less than 1800 mm in length.
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The brush shall be capable of being angled to the right and left with adjustable ground
pressure. Where necessary for the proper preparation of the surface, motor graders, rollers
and water trucks shall also be provided.
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5.9.3 Surface Preparation

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1 Immediately before applying the prime coat, all loose dirt, earth and other objectionable
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material shall be removed from the surface with a power broom of approved design and/or a
power blower as required, and any ruts, soft spots or unacceptable irregularities in the
surface shall be repaired in accordance with the instructions of the Engineer. If the Engineer
so requires, the surface shall be lightly bladed and rolled immediately before the application
of the prime coat, in which case brooming or blowing may not be required.
2 Priming will not be permitted when there is free water present on the surface.
5.9.4 Application
1 After preparing the road surface as above, the prime coat shall be applied by means of the
distributor at the temperature and rate shown in Table 5.12. Hand-spraying of restricted,
inaccessible areas is permitted, subject to the approval of the Engineer.
2 The surface of structures, kerbstones and other appurtenances adjacent to areas being
treated shall be protected in such a manner as to prevent their being spattered or marred.
3 The prime coat shall usually be applied to 1/3 or 1/2 of the road width at a time. When
applied in two or more lanes, there shall be a slight overlap of asphalt material along
adjoining edges of the lanes. It should be noted that no overlapping is allowed at the
transverse joints and that thick paper shall be used at the joint to protect the previous
application and the joining application shall begin on the paper. The paper used shall be
removed and satisfactorily disposed of by the Contractor after use. Care shall be taken that
the application of prime coat material at the junctions of spread is not in excess of the
specified amount. Excess bituminous material shall be removed from the surface.
5.9.5 Maintenance and Traffic
1 Traffic shall not be permitted on the primed surface until the asphalt material has penetrated
and dried and, in the judgement of the Engineer, will not be picked up under traffic. If it
becomes necessary to permit traffic before that time, but in no case sooner than 48 hours
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after the application of the asphalt material, blotter material shall be applied as directed by
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the Engineer and traffic shall be permitted to use the lanes so treated.
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2 Blotter material shall be spread from trucks operated backward so that the wheels will not
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travel in uncovered wet asphalt material. When applying blotter material to an asphalt treated
lane that adjoins a lane that has not been treated, a strip at least 200 mm wide along the
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adjoining edge shall be left devoid of blotter material in order to permit an overlap of asphalt
material.
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3 The Contractor shall maintain the primed surface in good clean condition and before the
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application of the next course, any surface irregularities shall be corrected and all excessive
blotter material, dirt or other objectionable materials shall be removed.
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5.10 TACK COAT

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5.10.1 General
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1 This work shall consist of furnishing and applying diluted emulsified asphalt to a previously
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prepared Base or Wearing courses, to provide bond for a superimposed course to the full
designated width.
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2 Tack coat shall not be applied when the ambient temperature is less than 13C nor during
rain, fog, dust storms or other unsuitable weather.
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1 The equipment used by the Contractor shall include liquid asphalt distributor as well as a
power broom and a power blower. Power broom shall be self-propelled and equipped with a
cylindrical, rotating nylon bristle Brush of not less than 760 mm in diameter and not less than
1800 mm in length. The brush shall be capable of being angled to the right and left with
adjustable ground pressure. In addition, the Contractor shall supply and use efficient and
approved equipment for diluting the emulsified asphalt with water.
5.10.3 Surface Preparation
1 The full width of the surface to be treated shall be cleaned with a power broom or power
blower to remove dust, dirt or other objectionable materials. All faulty or unsuitable patches,
excess cracks or joint filler and all surplus bituminous material shall be corrected in
accordance with the instructions of the Engineer. The surface shall be dry when treated.
5.10.4 Application
1 Immediately after cleaning the surface, the tack coat shall be applied by means of the
distributor at the temperature and rate directed by the Engineer. Hand spraying of restricted,
inaccessible areas is permitted, subject to the approval of the Engineer.
2 The diluted emulsion shall be applied at a rate shown in Table 5.12. The Contractor shall
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ensure that excessive application of tack coat is avoided.
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3 The surface of structures, kerbstones and other fixed objects adjacent to areas being treated
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shall be protected in such a manner as to prevent their being spattered or marred.
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5.10.5 Maintenance and Traffic
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After application, the surface shall be allowed to dry until it is in a proper condition of
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tackiness to receive the superimposed course. Tack coat shall be applied only so far in
advance of the superimposed course placement as is necessary to obtain this proper
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condition of tackiness.
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2 Until the superimposed course is placed, the Contractor shall protect the tack coat from
damage.
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3 If the tack coat is unavoidably damaged by rain or dust, it shall be allowed to dry, shall be
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cleaned again by a power broom or power blower and, if required by the Engineer, a
subsequent light application of tack applied to the surface. Where, in the opinion of the
Engineer, a tack coat is not necessary between layers of freshly placed courses, he may give
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instructions in writing to omit the tack coat. Any cleaning required in these areas shall be
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carried out before the application of the next course.

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5.11 THICKNESS AND LEVEL

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5.11.1 Thickness
1 Cores shall be taken to determine the thickness of asphalt paving courses. As determined
from each core, the thickness of a paving course shall not be less than that specified by more
than 5 mm in the case of a single-layered construction. Furthermore, the thickness of the
Wearing course shall not be less than that specified by more than 5 mm and the total
thickness of all asphalt paving courses combined shall not be less than that specified by
more than 10 mm.
2 In addition, the variations in the falls to cross sections of the road shall not vary from the
required value by more than 0.3 %. Any asphalt paving course containing deviations or
variations exceeding these tolerances shall be corrected or removed and replaced by the
Contractor, in accordance with the instructions and to the satisfaction of the Engineer.
3 Where any individual course is marginally out of tolerance on the low side, the Engineer may
allow adjustment in the succeeding course to correct the overall thickness of the pavement.
4 The tolerances herein specified shall not invalidate the tolerances set forth for the evenness
of surface of the asphalt paving course.
5 As directed by the engineer the laid thickness shall be checked by cutting test pits and/or
using Ground Penetrating Radar (GPR) for the determination of the structural capacity of the
pavement.
5.11.2 Transverse Evenness
1 The Engineer shall test the evenness of surface for each course of the various asphalt
paving courses to determine compliance.
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2 The Contractor shall put at the disposal of the Engineer a 3m long straight edge and a crown
template of sturdy and approved design and enough labour to assist in the checking
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operations. The maximum allowable differences between the pavement surface and the
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straight edge shall be 3mm. Transverse measurements shall be carried out every 20m of
road length for each lane.
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Any layer containing deviations or variations exceeding the tolerances specified here shall be
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corrected or removed and replaced in accordance with the instructions of the Engineer and to
his satisfaction.
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5.11.3 Evenness and Rideability

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1 Smoothness is a measure of the evenness and rideability of the pavement surface. It shall be
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measured on the driving surface of the completed pavement for all major roads before
opening to the traffic.
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2 Any section containing deviations or variations exceeding the criteria specified here or by the
Engineer shall be corrected or removed and replaced in accordance with the instructions of
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the Engineer and to his satisfaction at the Contractor’s cost.

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3 The minimum length of the rectification work undertaken shall be 100m.

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4 All rectified segments shall be re-tested following the completion of rectification work at no
additional cost to the client.
(a) Evenness
5 The evenness of the driving surface of road pavements shall be measured with a 3m rolling
straight edge along any line or lines parallel to the center line of the pavement on sections of
300m selected by the Engineer, whether or not it is constructed in shorter lengths. Sections
shorter than 300m forming part of a longer pavement shall be assessed using the number of
irregularities for a 300m length prorated to the nearest whole number. Where the total length
of pavement is less than 300m the measurements shall be taken in 75m lengths.
6 The number of deviations (from the bottom face of the straight edge) over the length of the
section greater than or equal to 4mm shall be counted. None of the measured deviations
shall exceed 6mm. The evenness of the driving surface of the tested section shall be within
the relevant limits given in Table 5.19.
Table 5.19
Evenness of Driving Surface
Section Length (m) Allowed number of deviations ≥4mm
300 20
75 9
(b) Rideability
7 For major roads the International Roughness Index (IRI) shall be used to monitor the
roughness and condition of the pavement surface. The acceptable IRI for ride quality shall be
decided by the Engineer.
8 The rideability of the driving surface of the completed pavement shall be measured in terms
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of the International Roughness Index (IRI) which shall be tested with a certified and
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calibrated Inertial Profiler meeting the requirements of ASTM E950–Class 1.
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9 The testing method shall be in accordance with ASTM E950. The IRI shall be calculated
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according to ASTM E1926.
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Calibration checks on the inertial profiler shall be conducted using test methods in
accordance with the manufacturer’s recommendations, at the beginning of the day of
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operation and at any other time the operator may suspect changes of system performance
since the last calibration.
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11 Calibration checks on the inertial profiler and all other quality checks shall be submitted in a
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method statement to the Engineer for approval.

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12 The selected measuring speed shall be the posted speed and within the range
recommended by the manufacturer and shall remain nearly constant during testing, not to
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exceed +/-5 km/h of the selected speed.
13 The profiler system shall stabilize at the test speed prior to entering the test sections. This
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requires bringing the profiler vehicle to the desired test speed at least 100 m prior to the
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beginning of the test location. Any Features along the test section such as bridges, culverts,
milepost or other pertinent information shall be identified. The test shall be conducted in the
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paving direction.
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14 The start and end point of the test section shall be automatically identified by using a photo
detector. The coordinates of the test section shall be identified by using a GPS.
15 Three runs of data collection (both wheel tracks in each lane) shall be conducted. The
processing of the data for IRI shall include calculating the average IRI value of the three runs
for the two wheel tracks. The processed data shall be reported on 25m and 400m sub-
sections calculated using the Moving Average statistical method and applying a 250mm
filtering.
5.12 PAVEMENT EVALUATION TECHNIQUES
1 Pavement evaluation tests shall be carried out for the completed pavement structure at any
point of the road as directed by the Engineer to assess the serviceability condition of the
pavement and verify compliance with specifications.
2 Pavement evaluation methods can be grouped into two main categories, destructive and
non-destructive.
3 The Contractor shall allow and provide all necessary arrangements for the execution of all
pavement evaluation test required by the Engineer.
4 As directed by the Engineer the structural ability of the pavement in terms of load-deflection
response and layer modulus shall be assessed by using the Falling Weight Deflectometer
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(FWD).
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5 The pavement surface friction shall be measured based on the Engineer request using the
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portable pendulum tester (ASTM E303), locked wheel tester (ASTM E274) or the sand patch
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method (ASTM E965).
5.13 PRODUCTION OF ASPHALT CONCRETE COURSES nt

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5.13.1 Weather Limitations
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1 Production and spreading of asphalt Concrete mix shall not be permitted when the ambient
temperature is less than 8 C, nor during rain, fog, dust-storms or other unsuitable weather.
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1 The equipment required for construction of the asphalt concrete courses shall include but not
be limited to the equipment mentioned in Clauses 5.3 to 5.6 of this Part, together with such
miscellaneous equipment and tools as required for the satisfactory preparation and
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performance of the work.

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2 All equipment shall be checked, calibrated and approved by the Engineer before use. The
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equipment shall be satisfactorily maintained and shall be used in an approved manner.

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3 Adequate equipment and labour shall be used so that there is continual production and
distribution of the asphalt course being constructed.
5.13.3 Survey and Preparation
1 The area to be paved shall be true to line and grade and shall have a properly prepared
surface before the start of paving operations.
2 When an asphalt concrete pavement course is to be placed on top of an existing pavement,

the existing pavement surface shall be prepared as designated by the Engineer.
3 Priming or tacking of surfaces to be paved shall be carried out as designated.

4 The surface of kerbs, vertical faces of existing pavements and all structures in actual contact
with asphalt mixes shall be painted with a thin and complete coating of tack coat as
instructed by the Engineer to provide a closely bonded, watertight joint.
5 All openings or structures in the road for water, drainage and other specified utilities shall be
constructed and their positions and levels determined before the start of paving operations.
5.13.4 Heating of Asphalt Binder
1 The 60/70 penetration grade bitumen shall be heated to a temperature of between 150 to 165
degrees centigrade.
2 Bitumen of other penetration grade shall be heated to yield viscosity's in the range of 150 to
300 centistokes (175 to 150 seconds Saybolt-Furol) when delivered to the mixer, as
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determined from the Temperature Viscosity Chart of the product used.
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3 Penetration Graded Asphalt Binders shall not be used if foaming occurs or shall it be heated
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above 175 C at any time.
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4 Polymer-modified binder shall be heated to a temperature specified by the supplier.
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5.13.5 Heating of Mineral Aggregate
1 When using 60/70 penetration grade asphalt binder the materials shall be thoroughly dried
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and heated so that their temperature is 165 to 180 degrees centigrade.

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2 When using asphalt binder of other penetration grade the materials shall be thoroughly dried
and heated so that their temperature is within ± 8 C of the temperature needed to satisfy the
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viscosity requirements of the asphalt cement.

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3 The moisture content of the heated and dried materials shall not exceed 1%.
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4 The quantity of materials fed through the drier shall in all cases be held to an amount which
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can be thoroughly dried and heated within the limits specified.

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5 The heated materials shall be screened into sizes such that they may be combined into a
gradation meeting the requirements of the Job Mix Formula and the hot aggregate storage
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bins shall be such as to minimise segregation and loss of temperature of aggregate.
6 Hot bins shall be drawn and cleaned of material at the end of each day's operation.
5.13.6 Proportioning and Mixing
1 The heated ingredients together with the mineral filler and bitumen shall be combined in such
a manner so as to produce a mixture which complies with the requirements of the Job Mix
Formula. Plant settings, once established, shall not be changed without the approval of the
Engineer.
2 Mineral filler, in a cool dry state, shall be proportioned into the mixer either with the aggregate
or after the introduction of the bitumen to avoid loss of fines that may occur in dry mixing as a
result of turbulence in the mixer.
3 In batch type plants a dry mixing period of not less than four seconds shall precede the
addition of the bitumen to the mix. Excess wet mixing shall be avoided. Wet mixing shall
continue as long as it is necessary to obtain a thoroughly blended mix but shall not exceed 75
seconds nor be less than 30 seconds.
4 Once approved, mixing times shall not be altered unless so ordered or further approved by
the Engineer.
5.14 HAULING EQUIPMENT
1 Vehicles used for the transport of aggregates or bituminous mix shall have tight, clean and
smooth insulated metal bodies and shall be free from dust, screenings, petroleum oil and
volatile or other mineral spirits which may affect the material being hauled. The vehicle metal
bed shall, if required, be sprayed with a minimum amount of soapy water or lime solution to
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prevent the bituminous mix from adhering to the bed. After spraying, the truck shall be raised
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and thoroughly drained and no excess solution shall be permitted. Use of diesel or other
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solvents to spray in the truck bed is prohibited.
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2 Provision shall be made for covering truck loads with canvas or other suitable material of
such size that the bituminous mix is fully covered.
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3 Any truck causing excessive segregation of material by its spring suspension or other
contributing factors, or that shows oil leaks in detrimental amounts, or that causes undue
delays, shall, upon the instruction of the Engineer, be removed from the work until such faults
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are corrected.
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4 End dump trucks shall be equipped with chains on the tail gates for control when dumping
the mix into the paving machine. Hauling trucks shall not be routed over wet or muddy
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access ways such that tires accumulate dirt that is deposited on the laying surface.
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5 The Contractor shall provide an adequate number of trucks of such size, speed and condition
to ensure orderly and continuous progress of the work all to the approval of the Engineer.
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5.15 OTHER EQUIPMENT

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5.15.1 Spreading and Finishing Equipment

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1 The asphalt mixture shall be fed to the paver by end tipping of the truck or by means of a
windrow elevator. The equipment for spreading and finishing the asphalt mixtures shall be of
an approved mechanical, self-powered electronic controlled floating screed type, capable of
spreading and finishing the mixture true to line, grade and required crown.
2 The pavers shall be self-propelled and equipped with hoppers and distributing screws of the
reversing type to place the mixture uniformly in front of adjustable electronic controlled
screeds. The pavers shall be so designed to allow a minimum paving width of 2 m, although
paving in widths of less than 3 m will require the approval of the Engineer.
3 Pavers shall be equipped with such provisions and attachments to suit paving widths
specified for road widening as well to as to suit paving on sloped sections. They shall be
equipped with fast and efficient steering devices and shall have reverse as well as forward
travelling speeds. The operational speed of the pavers shall be adjustable from 3 to 6 m/min
in accordance with the instructions of the Engineer.
4 The pavers shall employ mechanical devices as equalising runners, straight edge runners,
evener arms or other compensating devices to maintain trueness of grade and to confine the
edges of the pavement to true lines without the use of stationary side forms. The equipment
shall include blending or joint levelling devices for smoothing and adjusting longitudinal joints
between lanes. The assembly shall be designed and operated in such a manner that it will
place the material at the required compacted thickness.
5 Electronic screeds shall include automatic feed controls to maintain a constant level of
material along the full length of the screed, automatic grade control and automatic slope
control. Unless waived by the engineer, on projects with smoothness (IRI) requirements, the
paver shall carry minimum 9.0m long average beam equipped with an ultrasonic sensors
capable of sensing a pavement section at several spatially separated spots. The automatic
slope control shall be equipped with a proportioning manual override to enable smooth
transition of changing slope rate. Automatic screed controls shall be approved by the
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Engineer before use.
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6 Screeds shall be provided with devices for heating the screeds to the temperature required
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for the laying of the mixture without pulling or marring. Pavers shall also be provided with the
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standard attachable screed extensions. All screeds shall be of the vibrating type that permits
material to be tamped into position.
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The term "screed" includes any cutting, crowning or other physical action that is effective in
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producing a finished surface of the evenness and texture specified, without tearing, shoving,
or gouging.
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8 If, during construction, it is found that the spreading and finishing equipment in operation
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leaves in the pavement surface tracks or indented areas or other objectionable irregularities
that are not satisfactorily corrected by scheduled operations, the use of such equipment shall
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be discontinued and other satisfactory spreading and finishing equipment shall be provided
by the Contractor.
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5.15.2 Rolling Equipment

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1 Rolling equipment shall consist of vibratory steel-wheeled rollers, dead weight steel-wheeled
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rollers and pneumatic-tire rollers as required for proper compaction and finishing of the
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asphalt surface. Unless otherwise permitted, rollers shall be equipped with reversible or dual
controls to allow operation both forward and backward with the operator always facing in the
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direction of movement.
2 Steel-wheeled rollers shall be two-axle tandem rollers or three-axle tandem rollers. These
rollers shall be self-propelled and equipped with power units of not less than four cylinders
and under working conditions shall develop contact pressures under the compression wheels
of 45 to 65 kg/cm of width. Each two-axle roller shall have a minimum weight of 10,000 kg
each and three-axle roller shall have a minimum weight of 13,000 kg. Vibrating steel-wheeled
rollers shall have dual drums with a minimum weight of 7000 kg. Vibrating frequency shall be
between 2000 and 3000 cycles per minute with individual controls for each tandem drum.
Rollers shall be in good working condition and shall be equipped with a reversing clutch.
Rollers shall be equipped with adjustable scrapers to keep the wheel surface clean and with
efficient means of keeping them wet to prevent mixes from sticking. These surfaces shall
have no flat areas or projections which will mark the surface of the asphalt courses. The
three-axle rollers shall be equipped with a centre axle which may be operated either fixed or
floating. The three-axle tandem roller shall be so constructed that when locked in a position
for all treads to be in one plane, the roller wheels are held with such rigidity that, if either front
or centre wheel is unsupported the other two wheels will not vary from the plane by more than
6 mm. All steel-wheeled rollers shall be in good condition and the Contractor shall furnish to
the Engineer the manufacturer’s technical data for each roller and no roller shall be used
except after approval of the Engineer.
3 Pneumatic-tire rollers shall be self-propelled. The rollers shall be equipped with pneumatic
tires of equal size and diameter which are capable of exerting varying average contact
pressure. Pneumatic-tire rollers shall be in good condition and with enough ballast space to
provide uniform wheel loading as may be required. The Contractor shall furnish to the
Engineer charts or tabulations showing the contact areas and contact pressures for the full
range of tire inflation pressures and for the full range of tire loading for each type and size
compactor tire furnished and used in pneumatic-tire rollers. The total operating weight and
tire pressure may be varied by the order of the Engineer to obtain contact pressures which
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will result in the required asphalt course density.
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5.15.3 Liquid Asphalt Distributor
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1 The liquid asphalt distributor truck shall be of the pressure type with insulated tanks. The use
of gravity distributors will not be permitted. The distributor shall have pneumatic tires of such
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width and number that the load produced on the road surface shall not exceed 100 kg/cm tire
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width.
2 Spray bars shall have a minimum length of 2.4 m and shall be of the full circulating type.
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Spray bar extensions shall also be of the full circulating type. The spray bar shall be
adjustable to maintain a constant height above the surface to be treated.
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3 The spray bar nozzles shall be slotted and shall be of such design so as to provide a uniform
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unbroken spread of asphalt material on the surface. The valves shall be operated by levers
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so that one or all valves may be quickly opened or closed in one operation. The distributor
shall be equipped with a hose and nozzle attachment to be used for spotting areas
inaccessible to the distributor. The distributor and booster tanks shall be so maintained at all
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times as to prevent dripping of liquid asphalt material from any part of the equipment.
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4 The distributor shall be equipped with devices and charts to provide for accurate and rapid
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determination and control of the amount of liquid asphalt material being applied and with a
tachometer of the auxiliary wheel type reading speed in m/min. The spreading equipment
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shall be provided with a separate power unit for the pump or a variable displacement pump
driven by a hydrostatic transmission so that a uniform application of liquid asphalt material, in
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controlled amounts, may be made ranging from 0.15 to 5.0 kg/m . The distributor shall have
satisfactory heating equipment and thermometers in order to provide the full range of
application temperatures for the liquid asphalt material being used.
5 Before commencing the work and as required by the Engineer, the liquid asphalt distributor
shall be checked and calibrated such that the rate of transverse spread or longitudinal spread
shall not vary more than 10 % from the required rate of application.
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APPENDIX nt
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1 APPENDIX - ASPHALT WORKS........................................................................... 42

1.1 DEFINITIONS ........................................................................................................ 42
1.2 INTRODUCTION ................................................................................................... 44
1.3 SUPERPAVE DESIGN PARAMETERS ................................................................. 44
1.3.2 Traffic 44
1.3.3 Nominal Maximum Aggregate Size (NMAS) 45
1.4 SELECTION OF HMA PROPERTIES & REQUIREMENTS ................................... 46
1.5 OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS....................................... 47
1.5.2 Step1: Selection of Materials 47
1.5.3 Step2: Selection of a Design Aggregate Structure (DAS) 48
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1.5.4 Work Instructions of Step 2 Selection of DAS 50
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1.5.5 Step 3: Selection of the Design Asphalt Content 51
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1.5.6 Work Instruction of Step 3- Selection of DAC 52
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1.5.7 Nmax and Ndes Verification 52
1.5.8 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture 53
1.5.9
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Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity 54
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1.6 JOB MIX DESIGN PROPOSAL ............................................................................. 54
1.6.2 Acceptance of Job Mix Formula 55
1.6.3 Construction Quality Control: 56
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1.7 REFERENCES ...................................................................................................... 57

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1 APPENDIX - ASPHALT WORKS
1.1 DEFINITIONS
1 Superpave: Is an abbreviation of Superior Performing Asphalt Pavement. Superpave

system consist the following steps:
(a) Performance-Based Asphalt Binder Grading System

(b) Performance-Based Specifications of Materials & HMA.
(c) Test methods and practices for material selection & mix design.
(d) Performance prediction of HMA.
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2 Asphalt Binder Content (Pb): the percent by weight of asphalt binder in the total mixture.
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3 Initial Trial Asphalt Binder (Pbi): the percent by weight of the asphalt binder in the total
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mixture for each trial blend in the selection of the Design Aggregate Structure (DAS).
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4 Bulk Specific Gravity (G1, 2, to n; … Gsb, Gmb): the ratio of the weight in air of a unit volume
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of a permeable material (including both permeable and impermeable voids connected to
the surface of the aggregate particle) at a stated temperature relative to the weight in air of
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an equal volume of gas-free distilled water at the stated temperature. This definition
generally applies to individual aggregate stockpiles (Gl through Gn), the blended
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aggregate (Gsb, AASHTO T84, T85 and T100) or the compacted mix (Gmb, AASHTO T166 or
T275).
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5 Effective Binder Content (Pbe): the volume of the asphalt binder that is not absorbed into
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the aggregate but remains in the mixture to coat the aggregate particles.
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6 Effective Specific Gravity (Gse): the ratio of the weight in air of a unit volume of a
permeable material (excluding voids permeable to binder) at a stated temperature relative to
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the weight in air of an equal volume of gas-free distilled water at the stated temperature.
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7 Maximum Specific Gravity (Gmm): the ratio of the weight of a given volume of voidless
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(Va=0) loose HMA at a stated temperature (usually 77 °F (25°C)) to a weight of an equal

volume of gas-free distilled water at the same temperature (AASHTO T209).
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8 Voids in Mineral Aggregate (VMA): It is the total space between the aggregate particles
in the compacted paving mixture which includes 1) the air voids (Va) and 2) the effective
binder volume . The VMA is defined as the volume of void space between the aggregate
particles before adding the binder. Note: mineral aggregate is the aggregate which does not
include any or organic material but it is the material that consists of minerals and compounds
such as calcium, silicon, etc ….
9 Air Voids (Va): The total volume of the small pockets of air between the coated aggregate
particles throughout a compacted paving mixture, expressed as percent of the bulk
volume of the compacted paving mixture.
10 Voids Filled with Asphalt (VFA): the percentage portion of the volume of intergranular void
space between the aggregate particles (i.e. VMA) that is occupied by the effective asphalt
binder volume. It is expressed as the ratio of (VMA-Va) to the VMA.
11 Volume of Absorbed Binder (Vba): the volume of binder absorbed into the aggregate (equal
to the difference in aggregate volume when calculate with the bulk specific gravity and
effective specific gravity).
12 Dust to Binder Ratio (P0.075/Pbe): ratio by weight of the percentage of the aggregate
passing the 0.075 mm sieve (P200) to the effective binder content (Pbe).
13 Standard Axle: is 8.2 ton (18,000 lb) single axle with dual wheels; the center to center
distance of dual wheels is 34.29 cm (13.5 in); the tire pressure is 0.517 MPa (75 psi).
14 ESAL's: is an abbreviation of Equivalent Single Axle Load. The equivalency factor is the
number of repetition of the standard axle required to induce the same damage as the given
axle. AASHTO Road Test has shown that an equivalent number of the standard axle
can represent the damaging effect of the passage of an axle of any mass. This means that
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the ESAL is the number of applications of the standard axle that is equivalent in the damage
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to the pavement to an axle of any mass. The relationship is non-linear and is a fourth
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degree. For example, one application of a 16.2 ton single axle (36,000 lb twice as the
standard axel) was found to cause damage equal to approximately sixteen applications of
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the standard axle; or one application of a 16.2 tons axle were required to cause the same
damage or reduction in the pavement serviceability as sixteen applications of the
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standard axle. Also, one application of a 5.47 ton single axle (12,000 lb two thirds of the
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standard axel) was found to cause damage equal to approximately 0.2 applications of the
standard axle; or five applications of a 5.47 tons axle were required to cause the same
damage or reduction in the pavement serviceability as one applications of the standard
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axle.
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15 Standard Sieves: Superpave standard sieve sizes are 50.0, 37.5, 25.0, 19.0, 12.5, 9.5,
4.75, 2.36, 1.18, 0.6, 0.3, 0.15 and 0.075 mm
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16 Maximum Aggregate Size (MS): one standard size larger than the nominal maximum
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aggregate size (This definition applies only to Superpave mix design.)

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17 Nominal maximum aggregate size (NMAS): one standard size larger than the first sieve
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that retains more than 10 percent of the aggregate (this definition applies only to Superpave
mix design).
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18 Nini, Ndes and Nmax: These are the number of gyrations of the gyratory compactor at
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three compaction levels simulating the construction traffic for N ini, the design traffic for Ndes
and the maximum anticipated densification by the highest traffic for Nmax
19 Design Aggregate Structure (DAS): the aggregate blend meeting all Superpave
requirements.
20 Design Asphalt Content (DAC): the percent by weight of the asphalt binder in the total mix
selected at 4.0 % air voids in the mix meeting all Superpave requirements.
21 ePAVE3: is a user-friendly menu driven Excel program for the Superpave mix design
system. It is a decision making program that includes all the computations, requirements
and comparisons to design hot mix asphalt for a given project. ePAVE3 includes Superpave
requirements based on the latest (to date) Asphalt Institute Superpave Mix Design –
Superpave Series No. 2 (SP-2), third Edition 2001 and last edition of AASTO 2005
including M323 specification "Standard Practice for Designing Superpave HMA", and R35.
22 Polymer: An organic substance that is originated from petroleum gases. It is the product of
a complicated chemical process. The word “polymer” originally consists of two words
“poly” which means numerous and “meros” which means parts; therefore, polymer means
the substance with many parts. Polymers can be either copolymers or homopolymers. The
most common polymers that are used to modify the asphalt binder for road applications are
either “Elastomers” such as SBS or “Plastomers” such as EVA and Polyethylene.
23 Neat and Polymer Modified Binder (PMB): neat binder is a black or dark brown material
produced from refining of petroleum oil in petroleum refineries. The polymer modified binder
is a neat binder that has been modified by the addition of polymers. The purpose of blending
polymer and other chemical substances is to improve the neat binder Rheological properties
to achieve the Performance Grade (PG) requirements of Superpave grading system. This
process is complicated and involves accurate control of the process parameters such as
mixing mechanism, temperature, time, concentration and blending details
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1.2 INTRODUCTION
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1 This guide, which is based on ref. 1, should be considered as a guide to assist Engineers,
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consultants and contractors to design Hot-Mix Asphalt (HMA) using Superpave system. It is
the contractor full responsibility to select the applicable parameters for his project in liaison
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with the Engineer and LSA. This system was developed using the last editions of the Asphalt
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institute “Superpave Mix Design”, 2001, and AASHTO, 2005.
1.3 SUPERPAVE DESIGN PARAMETERS

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1 Before starting any HMA design using Superpave system for any project, the mixture and
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materials specifications and requirement must be identified. Superpave mix design system
requires three parameters in order to design a mix. These Parameters are:
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(a) Expected traffic volume in the project.

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(b) Nominal Maximum Aggregate Size (NMAS).

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(c) Location of the project.

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2 The contract documents shall specify and define the design parameters for the project. A
brief description of the basic design parameters is given in the following sections.
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1.3.2 Traffic
1 In Superpave, Traffic is defined as the total anticipated project level equivalent single
axle load (ESALs) on the design lane for a period of 20 years. To simplify the design
process, traffic class designations for each ESALs that appears in the Superpave system is
specified herein. If the contract documents do not specify the ESALs applicable to the
project, the Engineer can use the information provided in Table 1 to select the traffic classes
needed to establish Superpave criteria.
Table 1
ESAL and Traffic Designation
Class Designation ESALs Range Applications
Agricultural roads with light traffic , local

VL Very Light Less than 300,000
and city streets without trucks
L Light 300,000 to 3 million Agriculture, Feeder and collector roads
M Medium 3 million to 10 million Main roads and city streets
H Heavy 10 million to 30 million Highways and Expressway
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Heavily trafficked highways, industrial
VH Very Heavy More than 30 million
areas ...
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1.3.3 Nominal Maximum Aggregate Size (NMAS)
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1 Six Nominal Maximum Aggregate Sizes (NMAS) are identified in the Superpave system;
these are 37.5, 25.0, 19.0, 12.5, 9.5 and, 4.75 mm as specified in Table 2.
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Table 2
SUAERPAVE Standard NMAS mixtures
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Nominal Maximum Size Maximum Size

(NMAS) (MS)
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37.5 mm 50.0 mm
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25.0 mm 37.5 mm
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19.0 mm 25.0 mm
12.5 mm 19.0 mm
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9.5 mm 12.5 mm
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4.75 mm 9.5 mm
2 The selection of design NMAS for a specific layer is based on the general rule that the
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NMAS does not exceed half to one-third (1/2 to 1/3) the layer thickness. If the
contract documents do not specify the NMAS for the project, the Engineer can use the above
criteria and the information provided in Table 3 to select the NMAS of the project.
Table3
Recommended NMAS for Different Layer Types
Layer Recommended NMAS
Sand Mix 4.75 mm
Wearing coarse 9.5 or 12.5 or 19.0 mm
Base coarse 25.0 or 37.5 mm

1.4 SELECTION OF HMA PROPERTIES & REQUIREMENTS
1 Based on the specified design parameters (Traffic in ESAL, NMAS, geographic

location of the project and location of required layer to be designed), the mixture properties
and requirements can be selected. These properties include compaction level, which can be
identified from Table 4 and the properties of HMA, which can be identified from Table 5.
Table 4
Superpave Gyratory Compactive Effort (SGCE)
Traffic Gyrations
(ESAL, million) Nini Ndes Nmax
VL (< 0.3) 6 50 75
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L (0.3 to 3) 7 75 115
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M to H (3 to < 30) 8 100 160
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VH (> 30) 9
nt 125 205
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Table 5
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Superpave Criteria for the Mixture Design

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Traffic Class Designation (or ESAL,

Criteria million)
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VL L M H VH
Ninitial
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< 91.5 < 90.5 < 89.0
Ndesign 96.0
Required Density (% Gmm)
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Nmax < 98.0

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37.5 11.0 %
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Voids in the Mineral 25.0

Aggregate (VMA %min) 12.0 %
Nominal
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Maximum 19.0 13.0 %

Important Note: mixtures Size, mm
with VMA greater than 2.0% 12.5
above the minimum should 14.0 %
be avoided. 9.5 15.0 %
4.75 16.0%
37.5 64-80 64-78 64-75
25.0 67-80 65-78 65-75
19.0 70-80 65-78 65-75

Voids Filled with Asphalt, %
12.5 70-80 65-78 65-75
9.5 70-80 65-78 65-75
4.75 70-80 65-78 65-75

Traffic Class Designation (or ESAL,

Criteria million)
VL L M H VH
Dust Proportion (DP) Ratio, if gradation line is For all NMAS DP = 0.6 - 1.2, for NMAS 4.75
above the PCS DP = 0.9 - 2.0
Dust Proportion (DP) Ratio, if gradation line is 0.8 – 1.6

below the PCS.
Average Indirect Tensile Strength of the Dry Set Report

in the Moisture Sensitivity Evaluation, kPa
1.5 OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS
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1 According to SP-2 and AASHTO R 35, there are four major steps in the volumetric mix
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design process. These steps consist of
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(a) Material Selection, (Type of binder and aggregate).
(b) Selection of Design Aggregate Structure (DAS).
(c) Selection of Design Asphalt Content (DAC).
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(d) Evaluation of Strength and Moisture Sensitivity of the Mix.
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Step 4:
Strength and Moisture Sensitivity
Evaluation
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Step 3:
Selection of DAC
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Step 2:
Selection of DAS
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Step 1:
Selection of Materials
(Binder, Aggregate and Modifiers)
2 ePAVE3 program should be used to assist in the preparation of the mix design and obtain the
mix deign report summarizing the computations and test results. ePAVE3 mix design report
shall be submitted to the Engineer for acceptance then to LSA for approval.
1.5.2 Step1: Selection of Materials
1 This process includes the selection of the asphalt binder PG (ABPG) and the aggregates that
meet all Superpave criteria.
2 The selection of ABPG necessitates an understanding of the climatic condition (e.g.,

temperature) in which the pavement will be constructed and operated. This includes both
the average seven-day maximum high temperature and the single-day minimum low
temperature for the last twenty years and the latitude for that particular geographic location.
3 To account for traffic volume and speed or both, adjustments should be made to the selected
ABPG using AASHTO M332.
4 The requirements of the aggregate are selected based on the anticipated traffic and position
of the layer within the pavement. The quality criteria for Superpave aggregates are
summarized in Table 6. In order to be used in Superpave mixtures, the aggregate blends
must meet two sets of criteria known as source properties and consensus properties. Source
property requirements apply to each aggregate stockpile, but consensus properties apply
to the combined blend of multiple stockpiles. The consensus properties are mandatory
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for all Superpave aggregate blends while; source properties are left to the contracts.
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(a) Consensus Properties (Superpave Requirements):
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i. Coarse Aggregate Angularity, (CAA) ASTM D5821
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ii. Fine Aggregate Angularity, (FAA) AASHTO T304-Method A
iii. Flat and Elongated Particles (F&E) ASTM D4791
iv. Sand Equivalent, (SE) nt AASHTO T176
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(b) Source Properties (QCS Requirements):
QCS General Specifications, source properties are considered specific to the geology
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of a particular region and the experience with local materials.

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i. Toughness AASHTO T96

ii. Soundness AASHTO T104
iii. Clay lumps & friable particles AASHTO T112
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iv. Others.
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Table 6
Superpave Criteria for Aggregate Consensus Properties
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Traffic Class Designation (or ESAL, million) Layer Depth,

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Property
VH(>30) H(10to<30) M (3 to<10) L (0.3 to 3) VL (< 0.3) mm
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100/100 95/90 85/80 75/- 55/- < 100 mm CAA, %

min.
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100/100 80/75 60/- 50/- -/- > 100 mm
45 45 45 40 - < 100 mm FAA, %

min.
45 40 40 40 - > 100 mm
50 45 45 40 40 SE, % min
10 10 10 10 - F&E, % max
Note: CAA values (X/Y) denotes that X% of the coarse aggregate has one fractured face and Y%
has two or more fractured faces
1.5.3 Step2: Selection of a Design Aggregate Structure (DAS)
1 Once a group of aggregates has been identified, these aggregates are combined at
different percentages to produce at least three distinct blends conforming to Superpave
gradation requirements presented in Table 7 according to designed NMAS.
Table 7
Aggregate Gradation Requirements – Control Points
Nominal Maximum Aggregate Size, mm - Control Point (Percent Passing)
Sieve Size 37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
50.0 mm 100 - - - - - - - - - - -
37.5 mm 90 100 100 - - - - - - - - -
25.0 mm - 90 90 100 100 - - - - - - -
19.0 mm - - - 90 90 100 100 - - - - -
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12.5 mm - - - - - 90 90 100 100 - 100 -
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9.5 mm - - - - - - - 90 90 100 95 100
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4.75 mm - - - - - - - - - 90 90 100
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2.36 mm 15 41 19 45 23 49 28 58 32 67 - -
1.18 - - - - - - - - - - 30 60
0.075 mm 0 6 1 7 2 8 nt
2 10 2 10 6 12
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2 Primary Control Sieve (PCS) shown in Table 8 can be used to determine if the nominated
blend is fine or coarse gradation. If the gradation line passes below the PCS, it is considered
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as coarse graded and it is considered fine gradation if the line passes above the PCS.
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Table 8
Gradation Classification - PCS Control Points
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9.5mm 12.5mm 19mm 25mm 37.5 mm Nominal Maximum Size
2.36mm 2.36mm 4.75mm 4.75mm 9.5mm Primary Control Sieve Size

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47% 39% 47% 40% 47% %Passing PCS

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3 Typically, three blends are developed ranging from the coarse to the fine side of the
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Superpave control points for a given nominal maximum size (note: control points and PCS
differ for different NMAS). After selecting a blend (i.e. from the three trial blends), the
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aggregate consensuses properties must be confirmed to meeting Superpave criteria by

actual testing.
4 The most difficult part of designing an aggregate structure is the creation of the VMA
necessary to meet the volumetric criteria. The procedure is typically a trial and error
process; however, there are some general guidelines that will assist in obtaining the
VMA. The following recommendations may be tried to increase VMA:
(a) Move the gradation away from the maximum density line;
(b) Use highly angular particles;
(c) Use particles with a rough surface texture;
(d) Reduce the percent of natural sand and use more percent of the crushed sand;
(e) Reduce the amount of P200 used in the HMA; and
(f) Use S-shaped gradation curve.
5 A good design aggregate structure is one that is economical and meets Superpave
volumetric criteria.
1.5.4 Work Instructions of Step 2 Selection of DAS
1 To select the design aggregate structure, do the following:
(a) Obtain representative hot bin specimens from the plant.

(b) Determine the consensus properties, water absorption, bulk and apparent specific
gravities for each aggregate fraction.
(c) Grade the specimens using Superpave standard sieve set.
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(d) Input the values from two and three into ePAVE3 or combine manually. to
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develop three blends that meet the Superpave criteria (i.e. within the control points for
the design NMAS)
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(e) Estimate the initial trial asphalt binder content using ePAVE3 or by using formulas
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presented in ASSHTO R35.
(f)
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For unmodified asphalt binders, determine the mixing and compacting temperature for
the proposed asphalt binder as follows:
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(i) Measure the rotational viscosity using AASHTO T316 or ASTM D4402 at 135 C
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and 165 C.
(ii) Input the measured viscosities into ePAVE3. ePAVE3 will generate the viscosity-
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temperature relationship.
(iii) From the graph, determine:
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2 The mixing temperature at a rotational viscosity of 0.17 ± 0.02 Pa.s.

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3 The compaction temperature at a rotational viscosity of 0.28 ± 0.03 Pa.s.

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(g) For modified asphalt binders, determine the mixing and compaction temperature in
accordance with one of the methods presented in NCHRP 648.
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(h) Prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimens and
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two specimens to measure the Maximum Specific Gravity (Gmm) for each blend at the
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estimated initial trial asphalt content.

Note: small specimen size of 100 mm is used for mixes having NMAS of 19.0 mm or below.
(i) Leave the mix in the oven for two hours at the compaction temperature then
compact two 150.0 mm (or 100 mm) specimens for each blend using the Superpave
Gyratory Compactor (SGC) to Ndes according to AASHTO T312 (minimum number of
specimens is six).
(j) For the specimens that were compacted to Ndes, measure the bulk specific gravity
(Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
that is automatically recording the specimen height for each gyration.
(k) Measure the Maximum Specific Gravity (Gmm) for two specimens for each blend
according to ASSHTO T209.
(l) Input the measured values into ePAVE3. ePAVE3 will perform the computations,
display results, and check them against the criteria of the project.
(m) Check the results given by ePAVE3 for the three blends and select the most
conforming blend as the DAS; in case none of the three blends meets Superpave
criteria, repeat the design by developing additional aggregate blends from the same
source ; if the criteria is not met change the sources.
2 Preparation of the binder and aggregate mixtures for the gyratory compactor (SGC) should
be timed such that a minimum of 20 minutes is allowed between batches. Batched
specimens should be conditioned in a closed draft oven for a minimum of 2 hours ± 5
minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The
short time oven aging is performed to permit time for the aggregate to absorb the
binder. All specimens including those for SGC and maximum specific gravity tests, should
be cured the same amount of time.
1.5.5 Step 3: Selection of the Design Asphalt Content
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1 The selected aggregate blend (DAS) will then be mixed with four different proportions of the
binder as follows:
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(a) Estimated asphalt binder content corrected to give 4.0% air voids.
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(b) Estimated asphalt binder content corrected to give 4.0% air voids minus 0.5 %.
(c) nt
Estimated asphalt binder content corrected to give 4.0% air voids plus 0.5 %.
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(d) Estimated asphalt binder content corrected to give 4.0% air voids plus 1.0 %.
2 A sufficient amount of the proposed aggregate blend will need to be prepared to

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permit two specimens to be compacted in the SGC according to Superpave system for
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gyrations equal (Ndes), and the maximum specific gravity to be determined at each of the
four binder contents.
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3 Preparation of the binder and aggregate mixtures for the SGC specimens should be timed
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such that a minimum of 20 minutes is allowed between batches. Batched specimens should
be conditioned in a closed draft oven for a minimum of 2 hours ± 5 minutes prior to
compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven
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aging is performed to permit time for the aggregate to absorb the binder. All
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specimens including those for SGC and maximum specific gravity tests, should be cured the
same amount of time.
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4 The procedure used for design in the laboratory will need to closely match the field conditions
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at the time of construction. Failure to consistently test the materials at the same time interval
may result in a highly erratic all specific gravity values and possibly failure to achieve the
required VMA. After the necessary testing has been accomplished, the calculation of the
volumetric parameters can begin. The averaged results of the various volumetric calculations
need to be plotted relative to the corresponding binder content. The design binder content is
selected as that which satisfies the specified volumetric criteria at 4 percent air voids (refer to
AASHTO R35 for more details).
1.5.6 Work Instruction of Step 3- Selection of DAC
1 To select the deign asphalt content, do the following:
(a) After selecting the most conforming blend (DAS) from step 2, prepare enough
hot mix to make two 150 mm (or 100 mm) gyratory specimen and two specimens to
measure the Maximum Specific Gravity (Gmm) for four trial mixes using DAS of the
selected blend and four asphalt binder levels as specified in item (5.5.4) herein.
(b) Compact two 150.0 mm (or 100 mm) specimens for each mix using the Superpave
Gyratory compactor to Ndes according to AASHTO T312 (total number of specimens
are eight)
(c) For the specimens that were compacted to Ndes, measure the bulk specific gravity
(Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
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that is automatically recording the specimen height for each gyration.
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(d) Input the measured values into ePAVE3. The program will perform all calculations,
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produce the results and compare the results with required mix design properties for the
project.
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(e) ePAVE3 will generate the design curves, these are:
(i) % air voids vs. asphalt content. nt
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(ii) % VMA vs. asphalt content.
(iii) % VFA vs. asphalt content.
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(iv) % Gmm at Nini vs. asphalt content.

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(f) From the percentage, air voids vs. asphalt content curve determine the design asphalt
content (DAC) which corresponds to 4.0 % air voids.
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(g) Use the %VMA vs. asphalt content, %VFA vs. asphalt content % and %Gmm vs.
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asphalt content graphs to obtain the VMA, FVA and the % Gmm @ Nini values at the
design asphalt content.
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(h) Input the DAC, %VMA, %VFA % and Gmm @ Nini into the appropriate cells in
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ePAVE3. ePAVE3 will perform the computations, display results, and check them
against the criteria of the project.
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(i) If the mix properties at the design asphalt content conform to the Superpave criteria
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then go to the Nmax verification; if not then analyze, evaluate and modify the
design as needed until the mix properties at the design asphalt content (DAC)
conform to the criteria.
1.5.7 Nmax and Ndes Verification
1 After conforming to Superpave criteria, then do the Nmax verification as follows:
(a) Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
specimens and two Gmm specimens.
(b) Compact the specimens to Nmax using the gyratory compactor according to AASHTO
T312.
(c) Measure the Gmb at Nmax for the two specimens that were prepared using SGC and
measure the Gmm.
(d) Input the values into ePAVE3, which will perform the computations, provide the results,
and compare them with the Superpave criteria.
(e) Check the results of ePAVE3, if acceptable then the design is concluded if not
then redesign the mix.
2 After conforming that the mix properties at Nmax meet Superpave criteria, then do the Ndes
verification as follows:
(a) Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
specimens and two Gmm specimens.
(b) Compact the specimens to Ndes using the gyratory compactor according to AASHTO
T312.
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(c) Measure the Gmb at Ndes for the two specimens that were prepared using SGC and
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use the Gmm from the previous step. Obtain the specimen height at Ndes and Nini from
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the gyratory compactor that is automatically recording the specimen height for each
gyration.
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(d) Input the values into ePAVE3, which will perform the computations, provide the results,
and compare them with the Superpave criteria.
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(e) Check the results of ePAVE3, if acceptable then the design is concluded if not
then redesign the mix.
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1.5.8 Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture
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1 The identification of the combination of a design aggregate structure and design binder
content is now complete. The mixture now needs to demonstrate that it is capable of
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resisting the moisture induced damage. This evaluation is performed in accordance with
AASHTO T283.
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2 Moisture sensitivity evaluation requires that a total of six specimens consisting of the
proposed aggregate blend and binder at the design binder content, be prepared and
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compacted to approximately 7 ± 0.5% air voids. This group of specimens is divided into
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two subsets with three of the specimens being identified as the control specimens and
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the other three being identified as conditioned specimens.

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3 At the end of the conditioning period all of the specimens are loaded to failure in indirect
tension. Report the average Indirect Tensile Strength (IDT) of the dry subset in the mix
design report (see Table 5); and if the ratio of the average strength of the conditioned subset
to the control subset (retained strength) is more than or equal to 80% , then the mixture
passes the test. If the retained strength is less than 80%, then the mixture fails. The retained
strength can be increased by substituting part of the material finer than 0.075 mm by
mineral admixtures or by using chemical anti-stripping agents. Prepare another six (6)
specimens and test them as previously described. If this procedure does not improve the
retained strength to more than 80%, then the design process should be repeated using
different source.
1.5.9 Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity
1 To check the Strength and the moisture sensitivity of the designed mix, do the following:
(a) Prepare enough hot mix to make six 150 mm (or 100 mm) gyratory compactor
specimens using the selected gradation (DAS) and the design asphalt content (DAC).
(b) Use the Nmax verification densification data to identify the number of gyrations required
to achieve 7.0 ± 0.5% % air voids (i.e. %Gmm = 92.5 to 93.5 %).
(c) Compact six 150.0 mm (or 100 mm) specimens using the Superpave Gyratory
Compactor according to AASHTO T312 compactor (total number of specimens are
six) to a number of gyrations that will provide approximately 7.0 ± 0.5 % air voids.
(d) Use ASSHTO T283 to test the six specimens.
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(e) Input the measured values into ePAVE3. ePAVE3 will perform the computations and
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provide the results and compare them with the Superpave criteria
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(f) Check the results given by ePAVE3. Report the average IDT of the Dry group in the
mix design report (see Table 5). If the ratio of the average IDT of the conditioned
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subset to the control subset is 80% or more, then the mixture passes the test if not
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consider redesigning the mix and use some additives.
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1.6 JOB MIX DESIGN PROPOSAL
1 A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and submitted to
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the Engineer and LSA for approval. The JMF shall be prepared by the Contractor in precise
compliance with Superpave system. The Contractor shall select his sources of aggregate
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and bituminous material and, after sufficient quantities have been stockpiled or are available
for use, obtain representative specimens of the materials and test to determine if they
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conform to the requirements of the specifications.

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2 Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
Engineer, detailed information for each mix which he proposes to furnish. The information
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shall include, but not be limited to the following:

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(a) Copy of mix certificate approval obtained from LSA.

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(b) The source(s) of the aggregate for each mix.

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(c) Pertinent test data and a written certification that the aggregates conform to all of the
quality requirements specified herein and in section 5.2.
(d) Type of Asphalt modifier intended to be used in the project. The Asphalt binder
modifier shall be an approved modifier; along with the Certificate of Conformity of the
modified asphalt binder to the required grade according to the Superpave Performance
Based Grading System.
(e) Pertinent test data on the type and properties of the asphalt binder, modified asphalt
binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
(f) Superpave mix design report in ePAVE3 format.
(g) The type and location of plant to be used for mixing each mix.
(h) Type of Asphalt modifier intended to be used in the project. The Asphalt binder
modifier shall be an approved modifier; along with the Certificate of Conformity of the
modified asphalt binder to the required grade according to the Superpave Performance
Based Grading System.
(i) Pertinent test data on the type and properties of the asphalt binder, modified asphalt
binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
(j) Superpave mix design report in ePAVE3 format.
(k) The type and location of plant to be used for mixing each mix.
(l) The proposed beginning date for producing bituminous concrete mixtures.
(m) Any other support data and information special to the project (e.g. technical data
sheets of a polymer in case it was used).
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3 The Engineer shall be provided access to the materials sampling and testing operations at all
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times.
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4 At the same time that the above information is provided, the Engineer shall obtain one
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hundred (100) kilogram specimens of each individual aggregate size, eight (8) liters of
bituminous material and, when used, sufficient quantities of the mineral filler and the
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chemical admixture/asphalt modifier to complete two (2) proposed mix design checks,
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all representing the materials which the Contractor proposes to furnish. The final job
mix formula shall be made by using hot-bins aggregate.
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1.6.2 Acceptance of Job Mix Formula

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1 The Engineer shall review the JMF to determine that it contains all required information. If it
does not contain all required information, it shall be returned within seven (7) days to the
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Contractor for further action and resubmission by the Contractor.

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2 If the proposed JMF contains all required information but fails to meet all of the requirements
specified, it shall not be accepted by the Engineer and will be returned to the Contractor
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within fourteen (14) days. The Contractor shall prepare and submit to the Engineer a new
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JMF conforming to the requirements specified and propose a new date for beginning
production of the bituminous mixtures.
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3 When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all the
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requirements of the specifications, he shall order the Contractor to construct a minimum of

two hundred (200) meter long field test strip; but, not exceeding one day's production. The
test strip is used for three purposes:
(a) To check the contractor ability to produce the approved mix within tolerances.
(b) To check the contractor ability to construct and compact the mix to satisfy job
specifications.
(c) To check the riding quality according to project specifications.
4 The Engineer shall evaluate the test strip as to its constructability and compactability and the
mix for conformance to the laboratory tested JMF within the tolerances listed in Table 9. Five
(5) specimens shall be obtained from the test strip and tested.
5 If the Engineer is not satisfied with the results of the test strip, he shall state his
objections in writing and request a revised JMF and a new test strip.
6 When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all
requirements of the specifications and the test strip results are acceptable, he will issue
written acceptance to the Contractor to begin producing the proposed mixes. Production of
bituminous concrete mixtures shall not begin until the Engineer has given written acceptance
of the Job Mix Formula.
7 Acceptance of the JMF by the Engineer does not relieve the Contractor of his obligation to
produce bituminous concrete mixtures conforming to all specified requirements.
1.6.3 Construction Quality Control:
1 Testing to control the quality of bituminous concrete mixtures produced shall be the
responsibility of the Contractor.
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2 For each class of bituminous concrete produced and each day's production, the Contractor
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shall perform one (1) complete Superpave analysis at Ndes including gradation and asphalt
binder content, air voids, %VMA, %VFA, DP ratio, Indirect tensile strength on a specimen
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obtained from the discharge gate or hauling vehicle. In addition, the Contractor shall
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evaluate on a weekly basis the strength and moisture sensitivity of the mix from a specimen
obtained from the discharge gate or hauling vehicle.
3 No mixture conditioning is required when

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conducting quality control or quality
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assurance testing on plant-produced mixture.
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Table 9
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Superpave Job Mix Formula Tolerances for HMA Plant Mix

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Mix Composition Property Tolerance Limit

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Asphalt Binder Content (Pb) ±0.40

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Gradation Passing 4.75 mm and Larger Sieves ±5

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Gradation Passing 2.36mm to 150μm Sieve ±4

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Gradation Passing 75μm Sieve ±1.2

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Air Voids (Va) ±1.3
Voids in Mineral Aggregate (VMA) ±1.5
Field Density 92 to 94 (%Gmm)

1.7 REFERENCES
1) Hot Asphalt Mix Design System Using Superpave System Detailed in Asphalt Institute
SP-2 and the AASHTO 2005 Standards – MOT – Saudi Arabia, 2006.
2) AASHTO M323: Standard Specification for Superpave Volumetric Mix Design.
3) (NCHRP) Report 567: Volumetric Requirements for Superpave Mix Design.
4) (NCHRP) Report 409: Quality Control and Acceptance of Superpave-Designed Hot
Mix Asphalt.
5) (NCHRP) Report 539: Aggregate Properties and the Performance of Superpave-
Designed Hot-Mix Asphalt.
6) (NCHRP) Report 513: Simple Performance Tester for Superpave Mix Design.
7) (NCHRP) Report 648: Mixing and Compaction Temperatures of Asphalt Binders in
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Hot-Mix Asphalt.
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8) AASHTO T320: Standard Method of Test for Determining the Permanent Shear Strain
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and Stiffness of Asphalt Mixtures Using the Superpave Shear Tester (SST).
9) AASHTO T321: Standard Method of Test for Determining the Fatigue Life of
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Compacted Hot-Mix Asphalt (HMA) Subjected to Repeated Flexural Bending.
10)
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AASHTO T322: Standard Method of Test for Determining the Creep Compliance and
Strength of Hot-Mix Asphalt (HMA) Using the Indirect Tensile Test Device.
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11) AASHTO T340: Standard Method of Test for Determining the Rutting Susceptibility of
Hot Mix Asphalt (APA) Using the Asphalt Pavement Analyzer (APA).
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END OF PART
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Part 06: Concrete Road Pavements
6 CONCRETE ROAD PAVEMENTS .......................................................................... 3

6.1 GENERAL REQUIREMENTS .................................................................................. 3
6.1.1 Scope 3
6.1.2 References 3
6.1.3 Quality Control of Concrete Strength 4
6.2 TRIAL LENGTH ....................................................................................................... 5
6.2.1 General Requirements for Trial Length 5
6.2.2 Assessment of Trial Length 6
6.2.3 Approval and Acceptance of Trial Length 7
6.3 REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE .................................. 7
6.3.1 Materials and Mix Designs for Pavement Quality Concrete 7
6.3.2 Workability of Pavement Quality Concrete 7
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6.3.3 Trial Mixes 8
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6.3.4 Separation Membrane 8
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6.3.5 General Requirements for Steel Reinforcement 8
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6.3.6 Jointed Reinforced Concrete Slabs 9
6.3.7 Continuously Reinforced Concrete Slabs (CRCP or CRCR) 10
6.3.8 General Requirements for Transverse Joints nt 10
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6.3.9 Transverse Contraction Joints 11
6.3.10 Transverse Expansion Joints 11
6.3.11 Transverse Warping Joints 11
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6.3.12 Transverse Construction Joints 11

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6.3.13 General Requirements for Longitudinal Joints 12

6.3.14 Longitudinal Construction Joints 13
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6.3.15 Dowel Bars 13

6.3.16 Joint Grooves 16
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6.3.17 Groove Formers and Bottom Crack Inducers 17

6.3.18 Joint Filler Board 18
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6.3.19 Preparation and Sealing of Joint Grooves 18

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6.3.20 Sealing with Applied Sealants 19

6.3.21 Sealing with Compression Seals 20
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6.3.22 Joint Seals 21

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6.3.23 Joints at Manhole and Gully Slabs 21

6.3.24 Inspection of Dowel Bars 22
6.3.25 Side Forms, Rails and Guide Wires 22
6.3.26 Delivery, Storage and Batching of Concreting Materials 23
6.3.27 Mixing Concrete 24
6.3.28 Transport and Delivery 24
6.3.29 General Requirements for Construction by Machine 24
6.3.30 Construction by Fixed Form Paving Machines 25
6.3.31 Construction by Slip-Form Paving Machine 26
6.3.32 Construction by Small Paving Machines or Hand Guided Methods 26
6.3.33 Surface Textures 28
6.3.34 Strength 29
6.3.35 Trial Mixes 29
6.3.36 Trial Length 29
6.3.37 Surface Finish 30

6.4 REQUIREMENTS FOR CEMENT BOUND MATERIALS ....................................... 30
6.4.1 General Requirements for Cement Bound Materials 30
6.4.2 Batching and Mixing 31
6.4.3 Transporting 31
6.4.4 Laying 31
6.4.5 Compacting 32
6.4.6 Curing 32
6.4.7 Preliminary Trial 33
6.4.8 Cement Bound Material Category 1 (CBM1) 33
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6.4.12 Testing of Cement Bound Materials 35
6.4.13 Special Requirements for Cement Bound Materials 35
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6 CONCRETE ROAD PAVEMENTS
6.1 GENERAL REQUIREMENTS
6.1.1 Scope
1 This part of the specification covers the; materials, mix designs, production and laying of
pavement quality concrete, lean mix concrete and cement bound materials.
2 Related Sections and Parts are:
This Section
Part 3 ............... Earthworks
Part 4 ............... Unbound Pavement Materials
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Part 5 ............... Asphalt Works
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Section 5 - Concrete
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Part 16 ............ Miscellaneous - Pavement Quality Concrete
6.1.2 References
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1 The following standards are referred to in this part of the specification
BS 1377: Part 9 ..........Methods of testing soils – in-situ tests
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BS 1881...................... Methods of testing concrete -

BS 1924: Part 1 & 2.... Stabilised materials for civil engineering purposes
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BS 2499 & BS EN 14188 Hot applied joint sealants for road pavements
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BS 2752...................... Chloroprene rubber compounds

BS 3900: Part F12 ...... Determination of resistance to neutral salt spray
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BS 3963...................... Method for testing the performance of concrete mixers

BS EN ISO 11600 ...... Two part polysulphide sealants
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BS 4449...................... Reinforcing bars

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BS 4482...................... Cold drawn steel wire for reinforcing concrete

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BS 4483...................... Reinforcing mesh

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BS 5212: Part 1 & 2.... Cold applied joint sealants for concrete pavements
BS EN 206 & BS 8500 Supply of concrete
BS 7542...................... Methods for test of curing compounds for concrete
BS 812........................ Testing methods for aggregates
ASTM D3406 .............. Specification for joint sealant - hot applied elastomeric types
ASTM 7116 ................ Specification for joint sealant - hot applied elastomeric types (jet
fuel resistant)
ASTM D2628-91......... Specification for preformed joint seals
DTP ............................ Manual of contract documents for highway works -Volume 1

specification for highway works
6.1.3 Quality Control of Concrete Strength
1 Sampling and testing for, and compliance with the specified characteristics strength of
designed mixes shall be in accordance with BS EN 206 & BS 8500, except that it shall be at
the following rates of sampling and testing and meet the following requirements:
(a) Concrete cubes of the appropriate size shall be made, cured and tested in accordance
with BS 1881 respectively from concrete delivered to the paving plant, each group
being from a different delivery of concrete. At least 3 cubes shall be made per group
2
for each 600 m of concrete slab and not less than 6 groups shall be made each day,
2
for each type of mix. For areas less than 600 m , at least 4 cubes shall be made for
2
each 100 m or less. This rate of sampling and testing may be reduced at the
Engineer's discretion.
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2
(b) For areas of 600 m or more, one cube shall be tested in compression at 7 days and
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the other two at 28 days after mixing. Groups of four consecutive results at 28 days
shall be used for assessing the strength for compliance with BS EN 206 & BS 8500.
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2
For areas less than 600 m , two cubes shall be tested at 7 days and two tested at 28
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days and assessed in accordance with BS EN 206 & BS 8500.
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The ratio R between 7 and 28 day strengths shall be established for the mix to be used
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in the slab by testing pairs of cubes at each age on at least six batches of the
proposed mix or it shall be quoted by the supplier of the concrete. The average
strength of the 7 day pair of cubes shall be divided by the average strength of the 28-
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day pair of cubes for each batch and the ratio R shall be the average of these six
values. The ratio R shall be expressed to three decimal places.
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(d) If during the construction of the trial length or during normal working, the average value
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of any 4 consecutive 7 day test results falls below the strengths required then the
cement content of the concrete shall be increased by 5 % by mass or by an amount
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agreed by the Engineer. The increased cement content shall be maintained at least
until the four corresponding 28-day tests have been assessed. If the cement content is
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increased, the concrete mix shall be adjusted to maintain the required workability.
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(e) The values in columns 3 and 4 of Table 6.1 may only be used with the permission of
the Engineer when sufficient test results on trial mixes for calculating the ratio are not
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available. Once sufficient results are available from normal working the ratio R shall be
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calculated from the results available on Site.

(f) To assess the time for use of a concrete slab by traffic, the strength development rate
may be predetermined by trial mixes. Alternatively pairs of cubes shall be made for
2
each 600 m or less and stored alongside the pavement in containers or in such a way
that their sides are well insulated. If thermal insulation is used for accelerated curing
the cubes shall be similarly insulated. Pairs of cubes shall be tested at intervals
decided by the Engineer. Tests for compliance with the specified strength shall be
made in the normal way.
Table 6.1
7 Day Cube Strength
All Mixes, R PC Mixes, R not PFA or ggbs mixes, R

Grade of Concrete 2
available available not available N/mm
C40 43R 35 29
C30 33R 27 22
C20 22R 18 14
C15 17R 13 11
C10 10R 8 7
C7.5 7R 5.5 4.5
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6.2 TRIAL LENGTH
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6.2.1 General Requirements for Trial Length
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1 Except in rapid construction projects, at least one month prior to the construction of the trial
length of surface slabs or CRCR (Continuously Reinforced Concrete Road Base) the
Contractor shall submit for the Engineer's approval a detailed description of the proposed
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materials, mix proportions, plant, equipment and construction methods.

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2 No trials of new materials, plants, equipment or construction methods; nor any development
of them shall be permitted either during the construction of the trial length or in any
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subsequent paving work, unless they form part of further approved trials.
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3 The Contractor shall demonstrate the materials, mix proportions, plant, equipment and
method of construction that are proposed for concrete paving, by first constructing a trial
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length of slab, at least 150m but not more than 300 m, long for mechanised construction, and
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at least 30m long for hand guided methods, or otherwise as directed by the Engineer.
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4 The mix proportions decided by trial mixes may be adjusted during the trial but shall not be
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changed once the trial length has been approved except with the agreement of the Engineer.
5 The trial length shall be constructed in two parts over a period comprising at least part of two
separate working days, with a minimum of half the proposed trial lengths constructed each
day. The trial length shall be constructed at a similar rate to that which is proposed for the
main construction in the permanent works.
6 At least two transverse joints and one longitudinal joint of each type that are proposed for
unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in
the permanent works shall be constructed and assessed in the trial length.
7 If in the trial length expansion joints are not demonstrated, the first 2 expansion joints and at
least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for hand
guided method of construction laid in the main construction in the permanent works, shall be
considered the trial length for these joints.
8 One construction joint shall be demonstrated in each trial length of CRCP or CRCR.
6.2.2 Assessment of Trial Length
1 The trial length shall comply with the Specification in all respects, with the following additions
and exceptions provided in (a) through (d) below.
(a) Surface Levels and irregularity

(i) in checking for compliance the levels shall be taken at intervals of not more than
2.5 m along any line or lines parallel to the longitudinal centre line of the trial
length.
(ii) The maximum number of permitted irregularities of pavement surfaces shall
comply with the requirements for asphalt pavements as per Part 5
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for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on
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values for a 300 m length.
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(b) Joints
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(i) At least 3 cores of minimum diameter 100 mm shall be taken from the slab at
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joints to check the lateral and vertical location of joint grooves and bottom crack
inducers.
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(ii) After a minimum of 24 hours following construction the removable part of the
joint groove former shall be taken out and at least three joints and the sides of
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the groove shall be inspected for compaction. If there are voids the size and
number should be compared with a similar size section of the photograph for 3%
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excess voidage in BS 1881. If there is excess voidage, additional

compaction shall be provided and further joints inspected. The joints so
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exposed shall be temporarily or permanently sealed

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(iii) Alignment of dowel bars shall be inspected in any two consecutive transverse
joints. If the position or alignment of the dowel bars at one of these joints does
not comply after the next 3 consecutive joints of the same type have been
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inspected then the method of placing dowels shall be deemed to be satisfactory.

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(iv) If there are deficiencies in the first expansion joint constructed as a trial,
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the next expansion joint shall be a trial joint. Should this also be deficient further
trial expansion joints shall be made as part of a trial length which shall not form
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part of the Permanent Works, unless agreed by the Engineer.

(c) Density
(i) Density shall be assessed from at least 3 cores drilled from each part of the trial
length.
(d) Position of Reinforcement and Tie Bars
(i) Compliance for the position of steel reinforcement and for the position and
alignment of tie bars shall be checked by drilling additional cores from the slab
unless they can be determined from cores taken for density assessment.
6.2.3 Approval and Acceptance of Trial Length
1 Approval of the materials, mix proportions, plant, equipment and construction methods will be
given when a trial length complies with the specifications. The Contractor shall not proceed
with normal working until the trial length has been approved and any earlier defective trial
lengths have been removed, unless they can be remedied to the satisfaction of the Engineer.
2 When approval has been given, the materials, mix proportions, plant, equipment and
construction methods shall not thereafter be changed, without the approval of the Engineer
except for maintenance of plant. Any changes in materials, mix proportions, plant,
equipment, and construction methods shall entitle the Engineer to require the Contractor to
lay a further trial length as described in this Clause to demonstrate that these changes will
not adversely affect the permanent works.
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3 Trial lengths which do not comply with the Specification, with the exception of areas within
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the pavement surface which can be remedied shall be removed immediately upon notification
of deficiencies by the Engineer and the Contractor shall construct a further trial length.
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6.3 REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE
6.3.1 nt
Materials and Mix Designs for Pavement Quality Concrete
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1 The constituent materials and mix designs for pavement quality control shall be as per
Section 5: Part 16.
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6.3.2 Workability of Pavement Quality Concrete

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1 The workability of the concrete at the point of placing shall enable the concrete to be fully
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compacted and finished without undue flow. The optimum workability for the mix to suit the
paving plant being used shall be determined by the Contractor and approved by the
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Engineer.
2 The workability shall be determined by the compacting factor test, or the Vebe test or
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alternatively for concrete grade C20 or below, by the slump test, all in accordance with BS
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1881, at the minimum rate of one determination per 300 m2 of slab laid or 6 times per day,
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whichever is greater. For areas less than 300 m2 the rate shall be at least one determination
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to each 20 m length of slab or at least 3 times per day.
3 Alternatively the volumetric method of determining the Compacting Factor in BS 1881 may be
used. Tests for workability shall be carried out at the point of placing, in conjunction with
tests for strength and any tests for air content. The workability shall be maintained at the
optimum within the following tolerances.
Compacting Factor (CF) +0.03
Slump +20mm
Vebe +3 seconds or as agreed by the Engineer as a results of trial
mixes.
4 Any alteration to the optimum workability necessitated by a change in conditions shall be
agreed beforehand by the Engineer.
5 If any determination of workability gives result outside the tolerance, a further test shall be
made immediately on the next available load of concrete. The average of the two consecutive
results and the difference between them shall be calculated. If the average is not within the
tolerance or the difference is greater than 0.06 for CF or 20 mm for slump, or 6 seconds for
Vebe or other value agreed with the Engineer, subsequent samples shall be taken from the
delivery vehicles, which shall not be allowed to discharge into the Works until compliance
with the Specification has been established.
6.3.3 Trial Mixes
1 For concrete grades C15 and above the Contractor shall carry out laboratory trials of
designed mixes with the materials from all sources to be used in the Works, in accordance
with BS EN 206 & BS 8500 unless recent data relating entirely to the proposed mix is
approved by the Engineer.
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tin
2 The trial mixes shall be repeated if necessary until the proportions of ingredients are
determined which will produce a concrete which complies in all respects with the
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Specification.
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3 Apart from minor adjustments to the mix as permitted by BS EN 206 & BS 8500 any changes
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in sources of materials or mix proportions that are proposed by the Contractor during the
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course of the Works shall be assessed by making laboratory trial mixes and the construction
of a further trial length unless otherwise approval is given by the Engineer.
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6.3.4 Separation Membrane

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1 A separation membrane shall be used between jointed reinforced concrete surface slabs or
unreinforced concrete surface slabs and the sub base.
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2 Separation membranes shall be impermeable plastic sheeting 125 microns thick laid flat
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without creases. Where an overlap of plastic sheets is necessary, this shall be at least
300 mm. There shall be no standing water on or under the membrane when the concrete is
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placed upon it.

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3 Under CRCP and CRCR a waterproof membrane shall be provided, which shall be a
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bituminous spray before concreting. Where a bituminous spray has been used to cure
cement bound material or wet lean concrete then only those areas which have been
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damaged shall be resprayed after making good. The waterproof membrane shall be
bituminous cutback in accordance with clause 5.12 of this Section.
6.3.5 General Requirements for Steel Reinforcement
1 Reinforcement shall comply with any of the following standards and be in prefabricated
sheets or cages, or bars assembled on site and shall be free from oil, dirt, loose rust and
scale:
(a) (Carbon steel bars for the reinforcement of concrete) BS 4449

(b) (Cold-reduced steel wire for the reinforcement of concrete) BS 4482
(c) (Steel fabric for the reinforcement of concrete) BS 4483
(d) When deformed bars are used they shall conform to Type 2 bond classification of BS
4449.
2 Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in
longitudinal bars shall be not less than 35 times bar diameters or 450 mm which ever is
greater. In continuously reinforced concrete slabs (CRCP or CRCR) 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 by a process approved by the
Engineer.
3 Laps in a transverse reinforcement shall be a minimum of 300 mm. Where prefabricated
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reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is
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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
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met.
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4 If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal
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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.
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Reinforcement assembled on site shall be tied, or firmly fixed, by a procedure agreed with the
Engineer, at sufficient intersections to provide sufficient rigidity to ensure that the
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reinforcement remains in the correct position during construction of the slab.

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5 Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCR) 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
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reinforcement without distortion at the required position in the slab. The sheets shall be tied
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together at overlaps and after the second layer has been spread and compacted, the
reinforcement shall have the required cover.
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6 When a reinforced concrete slab is constructed at maximum width the transverse

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reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal

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diameter bars at 600 mm centres. 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
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sheets, or be continuous across the whole width of each slab.
6.3.6 Jointed Reinforced Concrete Slabs
1 The reinforcement shall be so placed that after compaction of the concrete, the cover below
the finished surface of the slab is 50 + 10 mm for slabs less than 200 mm thick, 60 + 10 mm
for slabs 200 mm or more but less than 270 mm thick and 70+20 mm for slabs 270 mm thick
or more.
2 The negative vertical tolerance shall not be permitted beneath road stud recesses.
3 Where traffic signal detector loops are to be installed, the minimum cover to the
reinforcement from the surface shall be 100 mm.
4 The vertical cover between any longitudinal joint groove forming strip and any reinforcement
or tie bars shall be at a minimum of 30 mm.
5 Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any
transverse reinforcement shall terminate at 125+25 mm from the edges of the slab and
longitudinal joints, where tie bars are used.
6 No longitudinal bars 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.
6.3.7 Continuously Reinforced Concrete Slabs (CRCP or CRCR)
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1 The reinforcement shall be Grade 460 deformed steel bars as detailed on the Contract
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Drawings.
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2 The reinforcement shall consists of bars assembled on site, or of prefabricated sheets.
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3 Except where otherwise shown on the Drawings the longitudinal bars shall be parallel to the
centre line of the road.
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4 The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at
the mid depth of the specified thickness of the slab + 25 mm. No longitudinal bar shall lie
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within 100mm of a longitudinal joint.

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5 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.
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Any transverse reinforcement shall terminate 125+25 mm from the edges of the slab and
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longitudinal joints where tie bars are used.
6.3.8 General Requirements for Transverse Joints

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1 Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and
shall be contraction, expansion or warping joints at the spacing shown on the Drawings such
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that for unreinforced concrete slabs the length/width ratio shall be not greater than 2.0.
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2 Joints in the surface slab and sub-base shall be staggered so that they are not coincident
vertically and are at least 1m apart.
3 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 at the
position proposed by the Contractor and agreed by the Engineer, except at road junctions or
roundabouts where the positions shall be as shown on the Drawings:
(a) Deviations of the filler board or bottom crack inducer from the intended line of the
joint shall be not greater than ± 10 mm.
(b) The best fit straight line through the joint groove as constructed shall be not more
than 25 mm from the intended line of the joint.
(c) Deviations of the joint groove from the best fit straight line of the joint shall be not
greater than 10 mm.
(d) When top groove formers and bottom crack inducers are used, the joint groove
as constructed shall be located vertically above the bottom crack inducer within a
horizontal tolerance of ± 25 mm.
4 Transverse joints on each side of a longitudinal joint shall be in line with each other and of
the same type and width. The position of the joints relative to manholes and gullies shall be in
accordance with the Drawings.
5 Transverse joints shall have a sealing groove which shall be sealed in compliance with
Clause 6.3.20 of the specification.
6.3.9 Transverse Contraction Joints
1 Contraction joints shall consist of:
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(a) Either a sawn joint groove, or
(b) a wet formed joint groove and a bottom crack inducer
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(c) dowel bars
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(d) a sealing groove.
6.3.10 Transverse Expansion Joints nt

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1 Expansion joints shall consist of:
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(a) a joint filler board

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(b) dowel bars

(c) a sealing groove.
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2 The filler board shall be positioned vertically within the prefabricated joint assemblies along
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the line of the joint and at such depth below the surface as will not impede the passage of the
finishing beams on the paving machines.
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3 The joint filler board together with the sealing groove shall provide a complete separation of
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adjacent slabs and any spaces around dowel bars and between the sub-base and the filler
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board shall be packed with a suitable compressible material after fixing the joint assembly.
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6.3.11 Transverse Warping Joints
1 Warping joints shall consist of:
(a) Either a sawn joint groove, or

(b) a wet formed joint groove and a bottom crack inducer
(c) tie bars
(d) a sealing groove.
6.3.12 Transverse Construction Joints
1 Construction joints made at the end of a working day in unreinforced concrete slabs and
jointed reinforced concrete slabs shall be expansion joints or contraction joints. In the event
of mechanical breakdown of the concreting machinery, or at the onset of adverse weather,
emergency joints may be formed.
2 Emergency joints in unreinforced concrete slabs shall be either contraction or expansion

joints not less than 2.5 m from the preceding or succeeding joint position.
3 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.
4 Construction joints in continuously reinforced concrete slabs (CRCP and CRCR) in an

emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement
without the approval of the Engineer. The stop end formwork shall be sufficiently rigid to
ensure that the longitudinal reinforcement and the tie bars projecting through the joint are
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held in the correct position.
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6.3.13 General Requirements for Longitudinal Joints
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1 Longitudinal joints shall be provided in surface slabs between or at the centre of traffic lanes
within the allowable positions as shown on the Drawings, so that bay widths are not greater
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than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with
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limestone aggregate) for reinforced concrete surface slabs with transverse reinforcement.
2 Longitudinal joints shall be provided in CRCR between lanes or at the centre of lanes, within
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a tolerance of +150 mm so that bay widths are not greater than 6 m (or 7.6 m with limestone
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aggregate).
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3 Joints in the surface slab, road base or sub-base shall be staggered so that they are not
coincident vertically and are least 300 mm apart. The positions of all longitudinal joints in any
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slab shall be agreed by the Engineer prior to construction of the slab.
4 Wet-formed longitudinal joints shall consists of wet-formed joint grooves, bottom crack
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inducer and tie bars except where transverse reinforcement is permitted in lieu.
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5 Longitudinal joints shall be constructed in the positions agreed by the Engineer within the
following tolerances:
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(a) Deviations of the bottom crack inducer from the intended line of the joint parallel
to the axis of the road shall not be greater than +13 m.
(b) The joint groove shall be located vertically above the bottom crack inducers within
a horizontal tolerances of +25 mm.
(c) The best fit line along the constructed joint groove, shall be not more than 25 mm
from the intended line of the joint.
(d) Deviations of the joint groove from the best fit line of the joint shall be not greater
than 10 mm.
6 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.
6.3.14 Longitudinal Construction Joints
1 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 greater.
2 A joint sealing groove is not required in construction joints in continuously reinforced concrete
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road bases. Where the edge of the concrete slab is damaged it shall be made good to the
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approval of the Engineer before the adjacent slab is constructed.
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6.3.15 Dowel Bars
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1 Dowel bars shall be Grade 250 steel complying with BS 4449 and shall be free from oil, dirt,
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loose rust and scale. They shall be straight, free of burrs and other irregularities and the
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sliding ends sawn or, if approved by the Engineer, cropped cleanly with no protrusions
outside the normal diameter of the bar. For expansion joints, dowel bars shall be 25mm
diameter at 300 mm spacing, 600 mm long for slabs up to 239 mm thick and 32 mm diameter
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for slabs 240 mm thick or more. For contraction joints, dowels shall be 20 mm diameter at
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300 mm spacing 400 mm long for slabs up to 239 mm thick and 25 mm diameter for slabs
240 mm thick or more.
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2 Dowel bars shall be supported 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
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shall ensure full recompaction of the concrete around the dowel bars and the surface finished
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by a diagonal finishing beam. Or a longitudinal oscillating float travelling across the slab.
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3 Dowel bars shall be positioned at mid-depth from the surface level of the slab ± 20 mm.
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They shall be aligned parallel to the finished surface of the slab, to the centre line of the
carriageway and to each other within the following tolerances:
(a) for bars supported on cradles prior to construction of the slab and for inserted
bars in two layers construction prior to placing the top layer:
(i) All bars in a joint shall be within ± 3 mm per 300 mm length of bars.
(ii) Two thirds of the bars shall be within ± 2 mm per 300 mm length of bar.
(iii) No bar shall differ in alignment from an adjoining bar by more than 3 mm per
300 mm length of bar in either the horizontal or vertical plane.
(b) for all bars, after construction of the slab:

(i) Twice the tolerances for alignment as in (i) above.
(ii) Equally positioned about the intended line of the joint within a tolerance of ± 25
mm.
4 Cradles supporting dowel bars shall not extend across the line of the joint.
5 Dowel bars, supported on cradles in assemblies, when subjected to a load of 110N applied at
either end and in either the vertical or horizontal direction (upwards and downwards and both
directions horizontally) shall not deflect more than the following limits:
6 Two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm
per 300 mm length of bar.
7 The remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm
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length of bar.
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8 The assembly of dowel bars and supporting cradles, including the joint filler board in the case
of expansion joints shall have the following degree of rigidity when fixed in position:
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9 For expansion joints the deflection of the top edge of the filler board shall be not
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greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
face of the joint filler board and distributed over a length of 600 mm by means of
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a bar or timber packing at mid depth and midway between individual fixings, or
300 mm from either end of any length of filler board, if a continuous fixing is used.
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The residual deflection after removal of the load shall be not more than 3 mm.
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10 The joint assembly fixings to the sub-base shall not fail under the 1.3kN load
applied for testing the rigidity of the assembly but shall fail before the load
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reaches 2.6 kN.

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11 The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail
before the load reaches 2.6 kN when applied over a length of 600 mm by means
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of a bar or timber packing placed as near to the level of the line of fixings as
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practicable.
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12 Failure of the fixings shall be deemed to be when there is displacement of the

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assemblies by more than 3 mm with any form of fixing, under the test load. The
displacement shall be measured at the nearest part of the assembly to the centre
of the bar or timber packing.
13 Dowel bars shall be covered by a thin plastic sheath over the whole length of the bar. The
sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The
sheathed bar shall comply with the following pull out test:
14 Four bars shall be taken at random from stock and without any special
preparation shall be covered by sheaths. The dowel bars which have been
sheathed shall be cast centrally into concrete specimens 150x150x450 mm,
made of the same mix proportions to be used in the pavement, but with a
maximum nominal aggregate size of 20 mm and cured in accordance with
BS 1881. At 7 days a tensile load shall be applied to achieve a movement
of the bar at least 0.25 mm. The average bond stress to achieve this movement
shall be not greater than 0.14 N/mm2.
15 For expansion joints a closely fitting cap 100 mm long consisting of waterproofed cardboard
or an approved synthetic material shall be placed over one end of each
dowel bar. An expansion space 10 mm greater than the thickness of the joint filler board shall
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be formed between the end of the cap and the end of the dowel bar.
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16 Tie Bars
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17 Tie bars in transverse or longitudinal joints shall be Grade 250 steel or Grade 460 deformed
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steel bars complying with BS 4449, in accordance with the requirements given below and
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Table 6.2. Deformed bars shall have Type 2 bond classification. Tie bars shall be free from
oil, dirt, loose rust and scale. Tie bars which are to be cranked and later straightened shall be
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Grade 250.
18 Tie bars projecting across a longitudinal joint shall be protected from corrosion by a flexible
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polymeric corrosion resistant coating, bonded onto the previously cleaned centre section,
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leaving between 250 mm and 300 mm of each of the bars uncoated.

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19 Where tie bars are cranked for construction joints and later straightened the coating shall be
shown to be capable of being straightened through 90 degrees without cracking. The coating
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shall also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS
3900 : Part F12, without showing any visible cracking, or corrosion of the protected part of
the bar. Any damage observed on the coating after straightening shall be made good before
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the concrete is placed.

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20 Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid
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assemblies with adequate supports and fixings to remain firmly in position during the
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construction of the slab.
21 Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from
above using a method which ensures recompaction of the concrete around the tie bars.
22 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 recompaction of the concrete around the
tie bars and adequate bond and which shall be approved by the Engineer.
23 Tie bars 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 or joint groove for slabs
200 mm thick or more, or 20 mm for slabs up to 200 mm thick.
24 At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m
long and of the same grade and size as the longitudinal reinforcement, and shall be fixed at
twice the normal spacing midway between the longitudinal reinforcement bars so that
750 mm ± 50 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, and extra longitudinal reinforcement bar at 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.
25 Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be
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placed at the same level as the transverse reinforcement and tied to the longitudinal
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reinforcement.
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Table 6.2
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Tie Bar Details
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Joints Diameter (mm) Grade of Steel Length (mm) Spacing (mm)
Transverse Twice the

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construction joints As for main spacing of

460 1500
in continuously reinforcement main
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reinforced concrete reinforcement

Emergency
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construction joints
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in jointed reinforced
250 or 1000 600
concrete slabs 12
460 deformed 750 600
other than at
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contraction or
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expansion joints
250 or 1000 300
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Warping joints 12
Longitudinal.
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All joints, except

250 or 1000 600
where transverse 12
reinforcement is
permitted in lieu
Note: The transverse reinforcement may be continued across the joint in reinforced concrete
with the approval of the Engineer if the bars are of a minimum nominal diameter of
12 mm and the bars are protected from corrosion and the cover is as required in this
Clause.
6.3.16 Joint Grooves
1 Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
2 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.
3 Sawn transverse joint grooves 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
1/4 and 1/3 of the specified depth of the slab and of any convenient width not less than 3mm.
The sealing groove may be constructed at the same time to be sawn to the required width
later. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall be
sawn immediately before sealing.
4 Construction Joint Grooves in Surface Slabs shall be formed by fixing a groove-former, strip
or cork seal along the top edge of the slab already constructed, before concreting the
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adjacent slab. Where the edge of the concrete is damaged it shall be ground or made good
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to the approval of the Engineer before fixing the groove forming strip.
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5 Alternatively the subsequent slab may be placed adjacent to the first and a sealing groove
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sawn later in the hardened concrete to the minimum depth required in Table 6.3 or to the
manufacturer's instructions if greater, and to sufficient width to eliminate minor spalling of the
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joint arris, up to a maximum of 25mm for longitudinal joints and 40mm for transverse joints.
The joints shall be sealed.
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6.3.17 Groove Formers and Bottom Crack Inducers
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1 Except where joint grooves are sawn, a bottom crack inducer shall be provided at each
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contraction, warping or longitudinal joint position.

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2 The bottom crack inducer shall be an approved 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
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firmly fixed to the sub-base so as to remain in position during the whole process of
constructing the slab.
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3 The combined depth of groove formers and bottom crack inducers shall be between 1/4 and
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1/3 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 20mm.
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4 The groove former for wet formed transverse joint grooves shall be made of an approved
rigid material of a width not greater than the required width of sealing groove as in Table 6.3.
The groove former shall be smooth sides with rounded protrusions no greater than 3mm. Any
removable part of the groove former may be tapered with a maximum difference in width of
2mm in 20mm depth.
5 Groove forming sealing strips for wet formed longitudinal joints shall be of firm compressible
strips of ethylene vinyl acetate foam of a minimum density of 90kg/m3, or synthetic rubber, or
equivalent material subject to approval by the Engineer. They shall have a minimum
thickness of 5mm and shall be sufficiently rigid to remain vertical and straight in the concrete
without curving or stretching. They shall be inserted continuously along the joint.
6 For CRCP Universal Beam Anchorage Transverse Joints one side of the beam shall be
separated from the CRCP slab by an expansion joint filler board against the vertical face and
ethylene vinyl acetate foam or similar compressible material, between 5 mm and 10mm thick,
stuck under the top flange.
6.3.18 Joint Filler Board
1 Joint filler board for expansion joints and manhole and gully slab joint shall be 25mm
thickness unless otherwise shown in the Drawings, within a tolerance of ± 1.5mm.
2 It shall be self expanding cork seal or a firm compressible material or a bonded combination
of compressible and rigid materials of sufficient rigidity to resist deformation during the
passage of the concrete paving plant.
3 The depth of the joint filler board for manhole and gully slabs shall be the full depth of the
slab minus the depth of the sealing groove. In expansion joints, the filler board shall have a
ridged top as shown on the Drawings, except where a sealing groove former is permitted by
the Engineer.
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4 Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the
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sheathed dowel bar.
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6.3.19 Preparation and Sealing of Joint Grooves
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1 All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed
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using one of the joint seals described. Additionally longitudinal joints which are sawn or
widened shall be sealed.
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2 Joint grooves shall be prepared in accordance with BS 5212: Part 2 and in compliance with
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(a) through (g) below:
(a) that part of the groove former used to form the sealing groove or any temporary seal
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shall be removed cleanly without damaging the joint arises to a minimum depth of
25 mm where compression seals are used or otherwise to such depth as will provide
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an applied seal to the dimensions as will provide in Table 6.3.

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(b) if joint grooves are not initially constructed to provide the minimum dimensions for the
joint seals as given in Table 6.3, they shall be widened by sawing. Joint grooves
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formed by tapered formers need not to be widened. The sealing grooves shall be
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cleaned out immediately after sawing using high pressure water jets, to remove all
slurry from the joint, before the slurry hardens.
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(c) if rough arrises develop when grooves are made they shall be ground to provide a
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chamfer approximately 5mm wide. If the groove is at an angle up to 10 degrees 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 10 degrees 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 25mm for longitudinal joints. If the spalling cannot be
so eliminated then the arris shall be repaired by an approved thin bonded arris repair
using cementitious materials.
(d) 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 characteristics compressive
2
strength of the concrete is expected to reach 15 N/mm . When compression seals are
used, the sides of the groove may be ground or wire brushed.
(e) for hot and cold applied sealants, compressible caulking material, debonding 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 described in Table 6.3 with the top
of the seal at the correct depth below the surface of the concrete.
(f) all grooves 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.
(g) 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
and with BS 5212: Part 2, except that 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.
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6.3.20 Sealing with Applied Sealants
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1 Sealing shall be carried out continuously along the full length of joint in any one rip, except for
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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
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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 10 C except
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between 8 C and 10 C it may be carried out when the temperature is rising.
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2 Hot applied sealants shall be heated in and applied from a thermostatically controlled,
indirectly heated dispenser with the recirculating pump. The sealant shall not be heated to a
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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
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the end of each day and reheated materials shall not be used.
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3 The components of cold-applied sealants shall be thoroughly mixed in the correct proportions
in accordance with the manufacturer's instructions using an automatic metering and mixing
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dispenser approved by the Engineer or, for hand application, using a power operated paddle
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mixer for sufficient time to produce homogenous mix without entrapped air. As soon as
possible after mixing and within the worklife of the sealant, the material shall be dispensed
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into the joint, or applied using a caulking gun, to the correct level below the concrete surface.
The tack-free time shall be achieved within 3 hours, for machine dispensed material, or within
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12 hours for hand applied material.
4 Test certificates shall be supplied from an approved testing laboratory stating that the sealant
complies with the relevant standard. Site testing of cold applied sealants shall be in
accordance with BS 5212: Part 2. Hot-applied sealants shall be sampled at the same rate
and checked for dimensions as in BS 5212: Part 2 and by the penetration test of the relevant
standard for the material.
Table 6.3
Dimensions of Applied Joint Seals
Type and Minimum Cold Hot Impregnated Depth of Seal

Spacing of Width (mm) Applied Applied Foam Below the
Joints (m) (mm) (mm) Compression Concrete
Strips (mm) Surface(mm)
Contraction:
15 and under 13 (Note 2) 13 15 30 5+2
Over 15 to 20 20 15 20 30 5+2
Over 20 to 25 30 20 25 40 5+2
Expansion All 30 20 25 40 7+2
Transverse 10 10 13 30 5+2
Warping
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Longitudinal 10 10 13 30 0 to 5
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Joints (if
sealed)
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Gully and 20 15 20 30 0 to 3
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Manhole Slabs
Note: (1) nt
The depth of seal is that part in contact with the vertical face of the joint groove.
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The depth of seal below the surface shall be taken at the centre of an applied
seal relative to a short straight edge, 150mm long, placed centrally across the
joint within 7 days of sealing.
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Note: (2) For cork seals other than in construction joints, grooves shall be 20 mm wide and
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50 mm deep.
6.3.21 Sealing with Compression Seals
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1 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 manufacturer's recommendations so that the
estimated maximum width of the joint opening shall be not more than 70% of the original
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width of the seal, the estimated maximum width being calculated on the basis of a movement
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of 4mm per 10m run of slab.

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2 The maximum calculated width of sealing groove shall be 30mm.

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3 The depth of groove shall be such that the contact face of the seal with the side of the groove
shall be not less than 20mm and that the top of the seal shall be a minimum of 3mm below
the surface of the concrete.
4 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.
5 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.
6 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.
6.3.22 Joint Seals
1 Joint seals shall consist of hot or cold applied sealants or compression seals or self
expanding cork seals.
2 Hot-applied sealants shall comply with ASTM Standard D3406, or D7116 (for fuel-resistant
sealant).
3 For joints between concrete surface slabs and bituminous surfacing, polymer modified
bitumen sealing strips shall be used and applied in accordance with the manufacturer's
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instructions. Hot-applied sealants complying with BS 2499 & BS EN 14188 may be used for
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such joints and in joints in asphalt kerbs laid on concrete pavements.
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4 Cold applied sealants shall be Type N complying with BS 5212: Part 1 except that Type F
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shall be used for lay-bys and hardstandings.
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For joints in kerbs and joints other than in pavements, seals may be any of the pavement
sealants if they have the suitable characteristics for the application. Also, gunning grade cold
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applied plasticised bituminous rubber sealant or gunning grades of two part polysulphid-
based sealants complying with BS EN ISO 11600 may be used.
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6 Alternatively, polyurethane-based sealing compounds may be used provided their

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performance is not inferior to BS EN ISO 11600 material.
7 Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing

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strip, or rubber seals made of polychloroprene elastomers complying with BS 2752 and
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conforming to the requirements of ASTM Standard D2628-91.
8 Compression seals shall be shaped so that they will remain compressed at all times and
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shall have a minimum of 20mm contact face with the sides of the sealing groove. If lubricant
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adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant
to abrasion, oxidisation, fuels and salt.
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9 Self Expanding Cork seals may be used in longitudinal joints, joints for manhole and gully
slabs and for transverse joints in short lengths of individual slabs or for replaced slabs.
6.3.23 Joints at Manhole and Gully Slabs
1 Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be
contained in separate small slabs, which shall be larger than the exterior of the manhole and
gully shafts, including any concrete surround less than 150mm below the underside of the
sub-base layer. The joint around the manhole or gully slab shall be vertical and incorporate
joint filler board but without dowel bars and tie bars.
2 Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint,
extending the gully slab as necessary to a maximum of 2m. Where this is impractical, an
extra tied warping joint shall be provided adjacent to or within the gully slab and at least 2m
from the next transverse joint. If the edge of an isolator slab is within 1m of any longitudinal
joint the isolator slab shall be extended to that joint.
3 Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or

longitudinal joints. If the manhole is within the middle third of the bay length a warping joint
shall be constructed on one side of the manhole slab across the whole width of the bay to the
nearest longitudinal joint.
4 Reinforcement as shown on the Drawings shall be placed in the main concrete slabs in the
corners between the manhole and gully slab and the transverse or longitudinal joints. Extra
reinforcement as described in the Contract shall be placed in reinforced concrete slabs
around the manhole or gully slabs.
5 Manhole and gully slabs shall have oblique corners, minimum 200mm long, at approximately
45 degrees to the axis of the pavement at all corners which are not adjacent to a transverse
or longitudinal joint in the main slab.
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6 Reinforcement as shown on the Drawings shall be placed in the gully or manhole slab and
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concrete grade C40 shall be placed by hand in the space between the main slab and the
manhole frame. The concrete shall be fully compacted and finished.
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7 A sealing groove shall be made directly above the joint filler board and sealed.
6.3.24 Inspection of Dowel Bars

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1 The position and alignment of dowel bars at contraction and expansion joints shall be
checked by measurement relative to the side form or guide wires.
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2 When the slab has been constructed, the position and alignment of dowel bars and any filler
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board shall be measured after carefully exposing them across the whole width of the slab.
When the joint is an expansion joint the top of the filler board shall first be exposed
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sufficiently in the plastic concrete to permit measurement of any lateral or vertical

displacement of the board. During the course of normal working these measurements shall
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be carried out at a rate of one joint per 1500m length of slab or one per 5 working days
whichever occurs the sooner. For small areas the rate shall be decided by the Engineer.
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3 If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the
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next two joints shall be inspected. If only one joint of the three is defective, the rate of
checking shall be increased to one joint per day until the Engineer is satisfied that
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compliance is being achieved. In the event of non-compliance in two or more successive

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joints, the Contractor shall revert to the construction of trial lengths and make any necessary
alterations to the concrete mix, paving plant or methods until the dowel bar position and
alignment is satisfactory.
4 After the dowel bars have been examined, the remainder of the concrete shall be removed
500mm on each side of the line of the joint, and reinstated to the satisfaction of the Engineer.
Alternatively if the dowels are examined in the penultimate joint of a day's work that joint shall
be made a construction joint for the next day's work and the remainder of the concrete in the
last slab may be discarded.
6.3.25 Side Forms, Rails and Guide Wires
1 All side forms and rails shall be made of steel and be sufficiently robust and rigid to support
the weight and pressure caused by the paving equipment. Side forms for use with wheeled
paving machines shall incorporate metal rails firmly fixed at a constant height below the top
of the forms.
2 The forms shall be secured by using not less than three pins for each 3m length having one
pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint,
free from play or movement in any direction. Forms shall be cleaned and oiled immediately
before each use. The rails or running surface shall be kept clean in front of the wheels of any
paving machine. The forms shall be straight within a tolerance of 3mm in 3m.
3 The forms shall be bedded on low moisture content cement mortar or concrete grade C7.5
and set to the pavement surface level as shown on the Drawings within a tolerance of +3mm.
The bedding shall not extend under the slab. There shall be no vertical step between the end
of adjacent forms greater than 3mm. The horizontal alignment for forms shall be to the
required alignment of the pavement edge as shown on the Drawings within a tolerance of +
10mm. The mortar or concrete bedding shall be broken out after use.
4 Side forms shall not be removed earlier than 6 hours after the completion of the construction
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of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie
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bars during the removal of the forms. If the removal of forms results in any damage to the
concrete the period of 6 hours shall be increased to that which is necessary to avoid further
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damage and the Contractor shall make good the damaged areas.
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5 Unless otherwise agreed by the Engineer, a guide wire shall be provided along each side of
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the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant
height above and parallel to the required edges of the slab as shown on the Drawings, within
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a vertical tolerance of + 3mm. Additionally one of the wires shall be at a constant horizontal
distance from the required edge of the pavement as shown in the drawings within a lateral
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tolerance of + 10mm.
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6.3.26 Delivery, Storage and Batching of Concreting Materials

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1 Aggregate for roadworks shall be delivered to and stored on the Site in one of the following
ways:
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(a) in separate nominal single sizes of coarse aggregate and fine aggregate.
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(b) as graded coarse aggregate of appropriate size and fine aggregate.

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(c) as all-in aggregate for grades C20 to below.

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2 If the Contractor proposes to blend aggregate off the site from two separate sources, he shall
obtain the Engineer's approval for the blending process, and for the arrangements for
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inspection during the course of the work.
3 Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Fine
aggregate nominally below 5 mm sieve size shall have been deposited at the site for at least
8 hours before use.
4 Batching plant and storage for aggregate shall comply with the following requirements as
appropriate to the method of delivery:
(a) if separate gradings of aggregate are stockpiled, separate accommodation shall

be provided for each nominal size of coarse aggregate or blend of fine
aggregate. The base for stockpiles shall be suitably surfaced to prevent
contamination of the aggregate. Drainage of the stockpile bases shall be
provided.
(b) aggregate shall be measured by mass and provision shall be made for batching
each nominal size or blend of aggregate separately, to the tolerances specified in
BS EN 206 & BS 8500.
(c) all-in aggregate shall be delivered and stockpiled in such a manner and to a
height that avoids segregation.
6.3.27 Mixing Concrete
1 Mixing concrete shall conform to the requirements of Section 5 Part 7 except as amended
herein.
2 Concrete shall be mixed on site in a stationary batch type mixer in compliance with BS EN
206 & BS 8500 unless with the approval of the Engineer, ready mixed concrete is supplied
from an approved source.
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3 The drums or blades of all mixers shall be operated at the speed using for testing, in
accordance with BS 3963 for the mix proportions required, within a tolerance of ± 1 revolution
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per minute. The mixing blades of a pan mixer shall be maintained within the tolerances
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specified by the manufacturers of the mixer and the blades shall be replaced when it is no
longer possible to maintain the tolerances by adjustment. All drums or pans which have
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been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh
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concrete is mixed in them.
4 The rated output of the batching and mixing plant shall exceed by at least a third the amount
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of concrete that is required at a constant rate to enable the paving train to move forward
continuously, at the planned rate of progress.
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6.3.28 Transport and Delivery

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1 Transportation, delivery of concrete shall conform to the requirements of Section 5 Part 8.

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6.3.29 General Requirements for Construction by Machine

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1 The concrete slab shall be constructed in a continuous process by either slip-form or by fixed
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form paving plant or by small paving machines or hand guided methods.

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2 The slab may be constructed in either one or two layers. In two layer construction the
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thickness of the top layer shall be not less than 50mm or twice the maximum size of the
coarse aggregate whichever is greater, and shall be at least 15 mm thick than the depth of
the groove former, if used.
3 While the concrete is still plastic its surface shall be brush-textured and the surface and
edges shall be cured.
4 The spreading, compacting and finishing of the concrete shall be carried out as rapidly as
possible and the paving operation shall be so arranged as to ensure that the time between
the mixing of the first batch of concrete in any transverse section of the slab and the
application of the sprayed curing membrane to the surface of that section shall not exceed
those given in Table 6.4.
5 Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge
next to a transverse joint while the concrete is plastic. In continuously reinforced concrete
pavement the slab shall be marked with the chainage at intervals not greater than 50m apart.
6.3.30 Construction by Fixed Form Paving Machines
1 A fixed form paving train shall consist of separate, powered machines which spread compact
and finish the concrete in a continuous operation.
2 Concrete shall be discharged without segregation into a hopper spreader which is equipped
with the means of controlling its rate of deposition onto the sub-base or onto the lower layer.
The concrete shall be spread in each layer without segregation and to a uniform
uncompacted density over the whole area of the slab.
3 The deposited concrete shall be struck off to the necessary level by the underside of the
hopper as it is traversed across the spreading machine.
4 The machine shall be capable of being rapidly adjusted for changes in average and
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differential surcharge necessitated by changes in slab thickness or crossfall. When the slab
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is constructed in two layers, the spreading of the concrete in the top layer shall follow the
completion of the bottom layer within the times given in Table 6.4.
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5 Prior to being compacted, the surface level of each loose spread layer shall be adjusted to
the correct surcharge by means of rotating strike-off blades or a screw device.
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The concrete shall be compacted by vibration or by a combination of vibration and
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mechanical tamping throughout the full depth of the slab. Poker vibrators shall be used in
each layer adjacent to the side forms and the edge of a previously constructed slab.
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7 The initial regulation and finish to the surface of the slab shall be effected by means of a
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beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam
shall be readily adjustable for both height and tilt.
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8 When grooves are wet-formed the concrete shall be recompacted around the former by a
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hand held vibrating plate compactor drawn along or on each side of the joint, prior to
regulation of the surface by the diagonal finishing beam. Or recompacted and finished if the
former is inserted after the finishing beam.
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9 The regulation and finishing of the surface of the slab shall be carried out by a machine which
incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both
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height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and
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span the full width of the slab. The leading beam shall be vibrated. The beams shall be
supported on a carriage, the level of which shall be controlled by the average level of not less
than four points evenly spaced over at least 3.5m of the supporting rail, beam or slab, on
each side of the slab that is being constructed. After the final regulation and before texture is
applied any excess concrete on top of the groove former shall be removed.
10 When a concrete slab is constructed in more than one width, flanged wheels on the paving
machines shall not be run directly on the surface of any completed part of the slab. The
second or subsequent slabs shall be constructed either by supporting machines with flanged
wheels on flat bottom section rails weighing not less than 15 kg/m laid on the surface of the
completed slab, or by replacing the flanged wheels on that side of the machines by smooth
flangeless wheel.. Flangeless wheels or rails shall be positioned sufficiently far from the
edge of the slab to avoid damage to that edge.
6.3.31 Construction by Slip-Form Paving Machine
1 A slip-form paving train shall consist of powered machines which spread, compact and finish
the concrete in a continuous operation.
2 The slip-form paving machine shall compact the concrete by internal vibration and shape it
between sliding side forms or over fixed side forms by means of either a conforming plate or
by vibrating and oscillating finishing beams.
3 The concrete shall be deposited without segregation in front of the slip-form 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 a screw auger device extending across the whole width of the
slab. The equipment for striking off the concrete shall be capable of being rapidly adjusted
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for changes of the average and differential surcharge necessitated by changes in slab
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thickness or crossfall.
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4 The level of the conforming plate and finishing beams shall be controlled automatically from
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the guide wires by sensors attached at the four corners of the slip form paving machine. The
alignment of the paver shall be controlled automatically from the guide wire by at least one
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sensor attached to the paver. The alignment and level of ancillary machines for finishing,
texturing and curing of the concrete shall be automatically controlled relative to the guide wire
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or to the surface and edge of the slab.
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5 Slip-form paving machines shall have a vibration of variable output, with a maximum energy
output of not less than 2.5 kW per metre width of slab per 300mm depth of slab for a laying
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speed of up to 1.5m per minute or pro rata for higher speeds. The machines shall be of
sufficient mass to provide adequate reaction on the traction units to maintain forward
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movements during the placing of concrete in all situations.

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6 Where grooves are wet-formed the concrete shall be compacted around the former by a
separate vibrating plate compactor with twin plates. The groove former shall be compacted to
the correct level by a vibrating pan which may be included with the transverse joint finishing
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beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the
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surface along the joint. Alternatively the surface shall be regulated with a longitudinal
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oscillating float travelling across the slab. Any excess concrete on top of the groove former
shall be removed before the surface is textured.
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7 Where a concrete surface slab is constructed in more than one width or where the edge
needs to be matched for level to another section of surface slab, and the surface levels at the
edges are not achieved, paving shall be carried out over separate fixed side forms to support
the edge to the required levels.
6.3.32 Construction by Small Paving Machines or Hand Guided Methods
1 As an alternative to fixed form or slip-form paving trains, the concrete slab may be
constructed using parts of trains, small paving machines, truss type finishing beams or hand
guided methods. Hand tamping beams may only be used for short lengths or infill bays or
tapers. Reinforcement, dowel bars and tie bars shall be supported in position, except where
two layer construction is used and reinforcement is placed on the bottom layer in a method of
construction approved by the Engineer.
2 The concrete shall be spread uniformly without segregation or varying degrees of

precompaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a
screed or auger so that the average and differential surcharge is sufficient for the surface of
the slab to be at the correct levels after compaction of the concrete.
3 The concrete shall be compacted by vibrating finishing beams across the slab and with
vibrating pokers adjacent to the side forms or the edge of a previously constructed slab. In
addition, internal poker vibration shall be used for slabs thicker than 200mm and may be
used for lesser thicknesses. When used, the pokers shall be at points not more than 500mm
apart over the whole area of the slab, or drawn continuously across the slab in front of the
finishing beams.
4 The finishing beams shall be metal with a contact face at least 50mm wide. They shall be
rigid or supported by a frame or truss without sag across the width of slab being paved. The
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beams shall be supported on rails or forms or an adjacent slab and shall be moved forward
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at a steady speed of 0.5m to 2m per minute whilst vibrating, to compact the concrete and to
produce a smooth surface finished to the correct crossfalls, crowns and levels relative to the
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top of the forms or adjacent slab.
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5 Any irregularities at wet-formed joint grooves shall be rectified by means of a vibrating float at
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least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be
regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further
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application of a twin vibrating finishing beam. All slabs shall be checked for level using a
straight edge at least 4m long. Any excess concrete on top of the groove former shall be
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removed before the surface is textured.

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6 The surface shall be brush textured.

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7 The surface shall be cured within the time to completion given in Table 6.4
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Table 6.4
Maximum Working Times
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Reinforced Concrete Slabs

All other Concrete Slabs
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Temperature of Consumed in Two layers

concrete at discharge
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Mixing first Mixing first

from the delivery between
layer to between layer to
vehicle layers in 2
finishing layers finishing
layer work
concrete concrete
Not more than 25 °C 3 hours 1/2 hour 3 hours 1 1/2 hours
Exceeding 25 °C 2 hours 1/2 hour 2 hours 1 hour
unacceptable
unacceptable
Exceeding 30 °C for paving
for paving
6.3.33 Surface Textures
1 After the final regulation of the surface of the slab and before the application of the curing
membrane, the surface of concrete slabs to be used as running surfaces shall be brush
textured in a direction at right angles to the longitudinal axis of the carriageway.
2 The texture shall be applied evenly across the slab in one direction by a brush not less than
450 mm wide. The texture shall be uniform both along and across the slab.
3 Curing
4 Immediately after the surface treatment, the surface and exposed edges of surface slabs
shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter
period). This will be by the application of an approved resin based aluminised curing
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compound, or polythene sheeting or an approved sprayed plastic film which hardens into a
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peelable plastic sheet. It shall be removed before road marking and opening to traffic.
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5 Resin based aluminised curing compound shall contain sufficient flake aluminium in finely
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divided dispersion to produce a complete coverage of the sprayed surface with a metallic
finish. The compound shall become stable and impervious to evaporation of water from the
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concrete surface within 560 minutes of application and shall have an efficiency index of 90%
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when tested as described in BS 7542.
6 The curing compound shall not react chemically with the concrete to be cured and shall not
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crack, peel or disintegrate within three weeks after application.

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7 Prior to application, the contents of any containers shall be thoroughly agitated. The curing
compound shall be mechanically applied using a fine spray onto the surface at a rate of at
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least 0.221L/m2. For the sides of slip-formed slabs or when the side forms are removed
within 24 hours and for small areas where mechanical application cannot be used, the
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compound shall be sprayed by hand lance at a rate of at least 0.271/m2. The rate of spread
shall be checked during construction of each trial length and subsequently whenever required
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by the Engineer.
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8 The mechanical sprayer shall incorporate an efficient mechanical device for continuous
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agitation and mixing of the compound in its container during spraying.

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9 Continuously reinforced concrete road bases shall also be cured. Wet lean concrete road
bases and sub-bases shall also be cured.
10 REQUIREMENTS FOR WET LEAN CONCRETE
11 Materials and Mix Designs
12 The constituent materials and the grades of concrete for wet lean mix shall comply with the
requirements of Section 5: Part 16.
13 Placing
14 Wet lean concrete shall be spread uniformly without segregation and without varying degrees
of pre-compaction.
15 The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that
after compaction the surface is at the required level.
16 Compaction
17 The spread wet lean concrete shall be compacted using internal or external vibration, or
combination of both to meet the required density.
18 Compaction and finishing to level shall be completed within the times given in Table 6.4.
19 Joints
20 At transverse and longitudinal construction joints between two separately constructed slabs,
the previously laid slab end or edge shall present a vertical face before construction of
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subsequent slabs.
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21 Longitudinal joints in wet lean concrete shall be staggered by at least 300mm from the
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position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse
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joints.
6.3.34 Strength
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1 From each sample, three cubes of the appropriate size shall be made, cured and tested in
compliance with BS 1881.
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2 One of each group shall be tested at 7 days and the other two at 28 days. The cubes shall
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be assessed for compliance on groups of four 28-day test results in accordance with BS EN
206 & BS 8500 for compliance with the grade required.
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3 If the average value of any four consecutive results of tests at 7 days falls below the required
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values the cement content of the mix shall be increased by an amount agreed with the
Engineer which shall be maintained until the corresponding 28-day test results have been
assessed.
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6.3.35 Trial Mixes

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1 Trial mixes complying with the requirements for pavement quality concrete shall be required
for designed mixes for Grade C15 and above, unless recent data relating to the proposed
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mix is approved by the Engineer.
6.3.36 Trial Length
1 At least 10 days before the start of the main wet lean concrete works a trial length of at least
400 m2 for mechanised construction and 30m for hand guided methods shall be constructed.
2 The trial length shall be laid to assess the suitability of the proposed material, plant,
equipment and construction methods to meet the requirements of the Specification.
3 The main construction in the permanent works shall not start until the trial length has been
4 If any trial length does not conform to the Specification another trial length shall be
constructed. Trial lengths not complying with the Specification shall be removed unless they
can be rectified to comply with the Specification to the satisfaction of the Engineer.
5 After approval has been given, the material plant, equipment and construction methods shall
not be changed without the approval of the Engineer.
6 Any proposed changes shall entitle the Engineer to require the Contractor to lay a further trial
length to assess the suitability of the proposed changes.
6.3.37 Surface Finish
1 The surface of the wet lean concrete after compaction and finishing and before overlaying
shall be free from ridges, loose material, pot holes, ruts or other defects.
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2 The surface texture shall comply with the sub-Clause for pavement quality concrete, Section
5: Part 16.
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6.4 REQUIREMENTS FOR CEMENT BOUND MATERIALS
6.4.1 General Requirements for Cement Bound Materials

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1 Cement bound materials shall be made and constructed as described in the following
clauses.
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2 Cement bound materials shall be tested in accordance with this specification for the
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requirements of Table 6.5

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3 Cement water and aggregates shall comply with the requirements of the Section 5: Part 16.
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4 Cement for use in all cement bound materials and aggregates for use in CBM3 and CBM4
shall be delivered and stored in compliance with the requirements of Section 5: Part 16.
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Table 6.5
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Cement Bound Materials Field Requirements

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Method of Moisture Minimum

Category Mixing Plant
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Batching Content Compaction
mix in place or
CBM 1 volume or mass NOTE 1 NOTE 2
mix in the plant
mix in place or
mix in the plant
CBM 3 mix in the plant mass NOTE 1 NOTE 2
mix in place or
mix in the plant
NOTE 1 to suit the requirements for strength surface, level regularity and finish
NOTE 2 95% of cube strength
Table 6.6
Cement Bound Materials Specimen Requirements
Minimum 7 days Cube

Strength
Compressive Strength
Category Curing
Testing Average Individual
(Note1) (Note2)
(MPa) (MPa)
BS 1924 Part 2 1990

CBM 1 BS 1924 Part 2 1990 4.5 2.5
or BS 1881Part 116
BS 1924 Part 2 1990

CBM 2 BS 1924 Part 2 1990 7.0 4.5
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or BS 1881 Part 116
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CBM 3 BS 1881 Part 111 BS 1881 Part 116 10.0 6.5
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CBM 4
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BS 1881 Part 116 15.0 10.0
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NOTE 1 The average strength of 5 cubes shall not be less than the stated figure
NOTE 2 The strength of any individual cube shall not be less than the stated figure
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6.4.2 Batching and Mixing

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1 Batching and mixing shall be carried out in the appropriate manner described in Table 6.5.
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2 Where the mix-in plant method is used and materials are batched by mass, the materials
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shall be batched and mixed in compliance with BS EN 206 & BS 8500. Where continuous
mixers are used and materials are batched by mass, the continuous mixers shall comply and
tested in accordance with BS 3963.
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6.4.3 Transporting
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1 Plant-mixed cement bound material shall when mixed be removed at once from the mixer,
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transported directly to the point where it is to be laid and protected from the weather both
during transit from the mixer to the laying site and whilst awaiting tipping.
6.4.4 Laying
1 All cement bound material shall be placed and spread evenly in such manner as to prevent
segregation and drying.
2 Spreading shall be undertaken either concurrently with placing or without delay.
3 Road base cement bound material shall be spread using a paving machine or a spreader box
approved by the Engineer and operated with a mechanism which levels off the cement bound
material to an even depth.
4 Cement bound material shall be spread in one layer so that after compaction the total
thickness is as specified.
5 At longitudinal or transverse construction joints, unless vertical forms are used, the edge of
compacted cement bound material shall be cut back to a vertical face where the correct
thickness of properly compacted cement bound material has been obtained.
6 In the case of cement bound sub bases under a concrete surface slab or continuously
reinforced concrete road base, longitudinal construction joints in the sub-base shall be
staggered by at least 300mm from the position of the longitudinal joints in the concrete
surface slab or continuously reinforced concrete road base, and by 1m for transverse joints.
6.4.5 Compacting
1 Compaction shall be carried out immediately after the cement bound material has been
spread and in such a manner as to prevent segregation.
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2 Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and
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transverse construction joints.
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3 Compaction shall be carried out in compliance with Table 6.5 and be completed within
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2 hours of the addition of the cement. The 2 hours may be varied at the discretion of the
Engineer if the preliminary trial indicates that this is necessary or appropriate. After
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compaction has been completed, compacting equipment shall not bear on cement bound
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material for the duration of the curing period.
4 The surface of any layer of cement bound material shall on completion of compaction and
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immediately before overlaying, be well closed, free from movement under compaction plant
and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated
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or otherwise defective areas shall be removed to the full thickness of the layer and new
cement bound material laid and compacted.
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6.4.6 Curing
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1 Immediately on completion of compaction, the surface of concrete or wet lean concrete or

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cement bound road bases and sub-bases shall be cured for a minimum period of 7 days
(unless the Engineer agrees to a shorter period) by one of the following methods:
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2 Covering with an impermeable sheeting with joints overlapping at least 300 mm and set to
prohibit egress of moisture. The sheeting shall be removed at the end of the curing period.
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3 Bituminous spraying which shall only be applied when there is no visible water. When the
cement bound material is likely to be exposed to high temperatures and solar radiation, the
bituminous spray shall be blinded with light coloured material.
4 Spraying with a curing compound.
5 Spraying with an approved plastic film which when hardened shall be removed before
applying any other pavement layer.
6 Whichever method is used, immediately prior to overlaying with any bituminous layer in
cationic bituminous tack coat shall be applied at a rate between 0.351/m2 to 0.551/m2.
6.4.7 Preliminary Trial
1 At least 10 days before the start of the main cement bound material works a trial area of at
least 400 m2 shall be laid to asses the suitability of the proposed materials, mix proportions,
mixing, laying, compaction plant and construction procedures.
2 When applicable the area shall include one longitudinal and one transverse construction joint.
The location and area of the trial shall be subject to the approval of the Engineer.
3 The rate of testing for the trial area shall not be less than that required in this section of the
specification.
4 The trial area will only be accepted for main construction in the Permanent Works if it
complies with the Specification.
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5 The main construction in the Permanent Works shall not start until the trial has been
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6 After approval has been given, the materials, mix proportions, mixing, laying compaction
plant and construction procedures shall not be changed without the approval of the Engineer
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who may require the Contractor to lay a further trial area to assess the suitability of the
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proposed changes.
6.4.8 Cement Bound Material Category 1 (CBM1)

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1 CBM1 shall be made from material which has a grading finer than the limits of Table 6.7
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2 In addition to the requirements of Table 6.6 the average compressive strength determined
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after immersion in water of five test specimens of CBM1 shall not be less than 80% of the
average compressive strength of five control specimens when subjected to the test
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procedure described in BS 1924: Part 2: 1990, clause 4.3.
3 After the 7 days immersion period the specimens shall not show any signs of cracking or
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swelling.
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Table 6.7
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Material for CBM1 - Limit of Grading

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BS Sieve Size (mm) Percentage by Mass Passing
50 100
37.5 95
20 45
10 35
5 25
0.600 8
0.300 5
0.075 0
NOTE: The particle size distribution shall be determined by the washing and sieving
method of BS812:
1 CMB2 shall be made from gravel sand, a washed or processed granular material, crushed
rock, all in aggregate, blastfurnace slag or any combination of these. The material shall fall
within the grading limits of Table 6.8.
2 The material shall have 10 % fines value of 50 kN or more when tested in accordance with
BS 812 with samples in a soaked condition.
3 In addition to the requirements of Table 6.6 the average compressive strength determined
after immersion in water of five test specimens of CBM2 shall not be less than 80% of the
average compressive strength of five control specimens when subjected to the test
procedure described in BS 1924: Part 2: 1990, clause 4.3. After the 7 days immersion period
the specimen shall not show any signs of cracking or swelling.
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Table 6.8
Material For CBM2 - Range Of Grading
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BS Sieve Size
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Percentage by Mass Passing
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50 100
37.5 95-100
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20 45-100
10 35-100
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5 25-100
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2.36 15-90
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0.600 8-65
0.300 5-40
0.075 0-10
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method of BS 812.
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1 CBM3 shall be made from aggregates as in the sub-Clause 6.5.9.
2 The grading of the aggregate shall be within the limits of Table 6.9.
1 CBM4 shall be made from aggregates as in sub-Clause 6.5.9
2 The grading of the aggregate shall be within the limits of Table 6.9.
Table 6.9
Material for CBM3 and CBM4 - Range of Grading
Percentage by Mass Passing.

BS Sieve Size (mm)
Nominal Maximum Size
40 mm 20 mm
50 100 -
37.5 95-100 100
20 45-80 95-100
5 25-5- 35-55
0.600 8-30 10-35
0.150 0.8* 0-8*
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0.075 0.5 0-5
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method of BS 812.
*0-10 for crushed rock fines
6.4.12 Testing of Cement Bound Materials nt
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1 Samples shall be provided in accordance with BS 1924: Part 1: 1990 Clause 5 from the laid
cement bound material before compaction. One group of five samples shall be provided from
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five locations equally spaced along a diagonal that bisects each 800 mm2 or part thereof laid
each day. The number of groups may be increased if required by the Engineer.
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2 One 150 mm cube shall be made from each sample taken in accordance with sub-clause 1
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of this clause. The cubes shall be made in accordance with BS 1924: Part 2: 1990, clause
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4.2.5 without further mixing of the material and within 2 hours of the addition of the cement.
Cubes shall be cured and tested in accordance with Table 6.6.
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3 To determine the wet density of cubes the mould shall be weighed prior to making the cube
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and the mass recorded. Immediately after completion of compaction, the cube and mould
shall be weighed and the mass recorded. These masses together with the nominal volume of
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the mould shall be used to derive the wet density of the cube.
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4 The in-situ wet density of a layer of cement bound material shall be taken as the average of
the wet densities at five locations equally spaced along a diagonal that bisects each 800 m2
or part thereof laid each day. The wet density at each location shall be the average of two
readings obtained using a nuclear density gauge complying with BS 1377: Part 9. The two
readings shall be taken at 180 degrees to each other using the same source rod hole. The
source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings
shall be taken within two hours of completing final compaction.
6.4.13 Special Requirements for Cement Bound Materials
1 Where specified in the contract documents or on the project drawings cement bound road
base in flexible composite construction shall be laid in individual widths with longitudinal
construction joints in locations as detailed below:
(a) Single All purpose. One longitudinal construction joint at the centre lane line marking.
(b) Dual 2 lane All-purpose. One longitudinal construction joint at the lane line marking.
(c) Dual 3 lane All-purpose. Two longitudinal construction joints, one at each of the lane
line markings.
(d) Dual 2 lane Motorway. Two longitudinal construction joints, one at the lane line
marking and one at the edge line marking between hard shoulder and left hand
lane.
(e) Dual 3 lane Motorway. Three longitudinal construction joints, one at each lane line
marking and one at the edge line markings between hard shoulder and left hand lane.
(f) Dual 4 lane Motorway. Four longitudinal construction joints, one at each lane line
marking and one at the edge line marking between hard shoulder and left hand lane.
2 Longitudinal constructions joints shall not be more than 150 mm from the centre of the centre
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line, lane line, or edge line marking, with individual widths not exceeding 4.75 m.
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3 Longitudinal construction joints shall not be located within the left hand lane or dual
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carriageways. At tapers and other changes in section the construction joint layout shall be
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agreed with the Engineer, and where necessary joints shall also be permitted within 150 mm
of the mid-point of the traffic lane.
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END OF PART
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Part 07: Asphalt Plants
7 ASPHALT PLANTS ................................................................................................. 3

7.1 ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE .............................. 3
7.2 ASPHALT PLANTS PRODUCTION CONTROL ...................................................... 4
7.2.1 Factory Production Control (FPC) 4
7.2.2 Factory Production Control Quality Plan 4
7.2.3 Organizational Structure 5
7.2.4 Internal Audits 5
7.2.5 Management Review 5
7.2.6 Document Control 5
7.3 PRODUCT REALISATION ...................................................................................... 6
7.3.1 Constituent Materials 6
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7.3.2 Customer Supplied Product 6
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7.3.3 Process Control 6
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7.3.4 Handling, Storage and Delivery 7
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7.3.5 Plant Calibration and Maintenance 7
7.3.6 Plant Quality Control Laboratory 8
7.4 nt
INSPECTION AND TESTING .................................................................................. 9
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7.4.1 General 9
7.4.2 Incoming constituent materials 9
7.4.3 Finished Asphalt Mixture 9
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7.5 NON-CONFORMITY ............................................................................................. 10

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7.5.1 General 10
7.5.2 Non-conformity of Material or Asphalt Mixtures 10
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7.6 INSPECTION, MEASURING AND TEST EQUIPMENT ......................................... 11

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7.7 PLANT GENERALLY ............................................................................................. 11

7.8 ASPHALT PLANT .................................................................................................. 12
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7.8.1 General 12
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7.8.2 Automatic Operation 12

7.8.3 Cold Bins System 12
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7.8.4 Drier 13
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7.8.5 Dust Collector 13

7.8.6 Screens 13
7.8.7 Hot Bins 13
7.8.8 Asphalt Binder Storage 14
7.8.9 Thermometric Equipment 14
7.8.10 Control of Mixing Time 14
7.8.11 Pugmill 14
7.8.12 Temporary Storage of Mix 15
7.8.13 Safety Requirements 15
7.8.14 Weigh-Box 15
7.8.15 Scales or Meters 16
7.8.16 Plant Control System 16
APPENDICES
APPENDIX “A” .................................................................................................................... 17
APPENDIX “B” .................................................................................................................... 22
APPENDIX “C” .................................................................................................................... 25
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7 ASPHALT PLANTS
7.1 ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE
1 Before loading, the bitumen manufacturer shall examine the shipping container and remove
all remnants of previous cargos that may contaminate the material to be loaded.
2 The manufacturer shall furnish with each shipment two (2) copies of the delivery ticket
containing the following:
(a) Consignees’ details.

(b) Net liters.
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(c) Net weight.
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(d) Type and amount of anti-stripping agent (if any).
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(e) Identification number (truck, car tank, etc.)
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(f) Destination.
(g) Date.
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(h) Loading temperature, and the recommended delivery temperature range.
(i) Specific gravity.
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3 The bitumen manufacturer shall deliver a signed Certificate of Compliance to cover the
quality and quantity of material and the condition of container for each shipment. Test results
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shall be provided with the shipment.

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4 Bituminous materials furnished without a Certificate of Compliance should not be introduced

into the work until the Contractor has had sufficient time to sample and test the delivered
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materials.
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5 The delivery tanker shall be insulated with a rock wool or similar material. Burner tubes shall
be designed so that the bituminous material is evenly heated with no hot spots within the
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tanker. Temperature gauges shall be calibrated and positioned such that the maximum
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temperature in the tanker shall be indicated. The temperature of unmodified and modified
bitumen during delivery shall be maintained in accordance with the manufacturer
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recommendations. Tankers shall be designed to enable the safe sampling of the bitumen
from the top of the tanker or from a sampling valve. Sampling shall not take place whilst the
tank is under pressure.
6 The Contractor shall obtain acceptance samples of bituminous material according to ASTM
D140 at the applicable point of acceptance.
7 For bituminous material used in direct application on the road, samples shall be taken from
each shipping container at the time of discharge into distributors or other conveyances on the
project.
8 For bituminous material initially discharged into storage tanks on the project, samples shall
be taken from the line between the storage tank and the distributor or the asphalt plant after
each delivery. Samples shall be taken after a sufficient period of circulation has taken place
to ensure samples are representative of the material in the storage tank.
9 The manufacturer of bituminous materials shall test all materials produced and the test
results retained for reference. Each shipment of bituminous material delivered to the asphalt
plant shall be sampled. The samples shall be numbered consecutively and identified by
project, type and grade of bituminous material, date of delivery and use. Samples testing
frequency shall be based on LSA and the Engineer approval.
10 Each bitumen delivery and storage tank and its associated delivery pipe and control valve
must be independently and uniquely identified with the tank number.
11 Storage tanks must also display the grade of bitumen held in the tank.
12 Adequate and reliable means of gauging the bitumen tank contents and ullage must be
available at the discharge point.
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13 Vent pipes must be fitted in bitumen tanks and located where they do not pose a risk to any
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personnel or delivery vehicles and must be kept clear at all times.
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14 It is recommended that bitumen tanks should be fitted with a correctly designed drain valve to
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enable the safe emptying of the tank for cleaning and maintenance. In the absence of a drain
valve, a specific risk assessment must be carried out prior to any uplift of product.
15 nt
Samples must not be taken from the bitumen delivery vehicle or hoses at the delivery site
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unless equipment is fitted to do so safely.
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16 If there is a requirement to take bitumen samples a purpose designed valve should be

permanently fitted to the tank (or corresponding pipework).
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7.2 ASPHALT PLANTS PRODUCTION CONTROL

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7.2.1 Factory Production Control (FPC)

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1 The Organization shall establish and operate a permanent factory production control system
to ensure delivery of the quality requirements of the project specification whilst
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maintaining a regime of continuous improvement and ensure the competence and

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training of staff and operators. The Organization shall document and maintain the FPC
system in which procedures, regular inspections and tests and/or assessments and the
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use of the results to control raw and other incoming materials or components, equipment,
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the production process and the product.
2 A sample plant inspection checklist, which includes the minimum items to be covered as part
of LSA inspection, Engineer inspection and producer internal audit system, is provided in
Appendix “C”.
7.2.2 Factory Production Control Quality Plan
1 The Organization shall establish and maintain FPC documentation for each asphalt
production site used to supply the works.
2 The FPC documentation shall include a means for identifying and detailing the specific
processes that directly affect the quality of the asphalt. This shall particularly address:
(a) Producer’s organizational structure relating to conformity and quality.

(b) Document control.
(c) Control procedures for constituent materials and purchaser supplied product.
(d) Process control
(e) Requirements for the handling and storage of the product.
(f) Plant calibration and maintenance.
(g) Quality control laboratory calibration and maintenance.
(h) Requirements for inspection and testing of processes and products.
(i) Procedures for handling non-conformity.
7.2.3 Organizational Structure
1 The responsibility, authority and inter-relation of all personnel who manage, perform and
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verify work affecting conformity and quality shall be defined in the quality plan, particularly for
personnel who have authority to:
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(a) Initiate action to prevent the occurrence of product non-conformity.
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(b) Identify and record any product quality problems.
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The producer shall identify a person with appropriate authority, knowledge and experience to
supervise Factory Production Control and to ensure that the requirements of the quality plan
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are implemented and maintained. The person identified may exercise such supervision over
a group of plants.
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3 The management structure shall be documented. Names, affiliations, and positions of

principal staff shall be listed. The organization chart shall clearly define relationships with
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other partner organizations where applicable.

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7.2.4 Internal Audits

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1 The Organization shall carry out internal audits to verify which activities comply with the
planned arrangements and to determine the effectiveness of the Factory Production Control
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system. Audits shall be scheduled on the basis of the status and importance of the activity.
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The audits and follow up action shall be carried out in accordance with documented
procedures. The results of the audits shall be documented and brought to the attention of the
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personnel having responsibility in the area audited. The management personnel responsible
for the area shall take timely corrective action on the non- conformities found by the audit and
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shall keep a record of the action taken.
2 The frequency of such audits shall be that each area of process is audited at least annually.
7.2.5 Management Review
1 The system shall be reviewed at least annually by management to ensure its continuing
suitability and effectiveness.
7.2.6 Document Control
1 The producer shall establish and maintain documented procedures to control all documents
and data that relate to the requirements of these specifications.
2 The producer shall maintain all documents related to daily production quality records, test
methods, practices, procedures, and specifications.
3 Records relating to Factory Production Control shall be maintained and accessible by the
Organization and shall be produced if requested by the Engineer or any authorized audit
body.
4 Management review, internal audits, 3rd party assessment, and inspection and testing of
finished asphalt shall be kept for a minimum of ten years. All other quality records shall be
kept until at least five years after the completion of the project, or longer as the Organization
requires.
7.3 PRODUCT REALISATION
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7.3.1 Constituent Materials
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1 Adequate supplies of constituent materials shall be available to ensure that the
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planned rates of production and delivery can be maintained.
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2 The specification and tolerances for incoming constituent materials shall be established
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and communicated to suppliers by appropriate traceable and confirmable means.
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3 The control procedures shall verify that suppliers of incoming materials are capable of
providing the required quality of materials.
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4 Different material types or grades shall be transported and stored in such a manner
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as to avoid intermingling, contamination or deterioration which may adversely affect the

quality of the product.
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5 The general requirements of this clause shall be translated into more detailed plant
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specific requirements within the FPC and include the following:
(a) Procedures for the control of aggregates delivered to a depot or plant site.
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(b) Requirements for labelling of storage bays and silos.

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(c) Requirements for heating, temperature control and insulation of binder tanks, pipes
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and pumps.
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(d) Requirements for controlling delivery of binders into the correct tanks, including
stirrers/agitators and labelling of tanks, and the selection of the correct tanks for use.
(e) Requirements for the control of additives.
(f) Requirements for the manufacture of polymer modified binders at site by the
Organization or its supplier, where applicable.
7.3.2 Customer Supplied Product
1 Any constituent material supplied by the customer for inclusion in the asphalt shall be
handled, stored and maintained free of contamination by the Organization.
7.3.3 Process Control
1 The FPC quality plan shall include the following items of process control:
2 A description of the flow of materials and the processes carried out on them from receipt at
the plant to delivery to the job site. This shall incorporate a flow diagram.
3 A statement of the production control processes necessary to maintain and regulate the
quality of material in conformity with the specification. This will include the procedure for the
control of batching instructions.
4 A schedule for monitoring the performance of the process, which is shown in Table A-1 in
Appendix “A”, resulting in a record of plant performance against stated tolerances.
5 A detailed method statement for the production of polymer modified binder including storage
and quality control, and the procedure for the handling of nonconforming product.
7.3.4 Handling, Storage and Delivery
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1 The FPC quality plan shall contain procedures to ensure that the asphalt mixture is handled,
stored, discharged and delivered at the specified temperature range, minimizing segregation
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and degradation.
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2 The asphalt mixture shall be identifiable and traceable with regard to its production data and
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can be referenced from information on the delivery ticket from its manufacture to its point of
installation. The quality plan shall however make clear the point to which the Organization’s
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responsibility for handling storage and delivery extends.
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3 The quality plan shall describe the characteristics of any hot storage system and define its
mode of operation. The Organization shall ensure thorough checks, inspections and records
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that such systems are used correctly and that bituminous mixtures maintain their suitability
for use.
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4 Bituminous materials shall not be heated during the process of its manufacture or during
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construction so as to cause damage to the materials as evidenced by the formation of

carbonized particles.
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7.3.5 Plant Calibration and Maintenance

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1 The FPC quality plan documentation shall identify those items of measuring equipment which
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require calibration and the frequency of such calibration which shall comply with the
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requirements of QCS 2014, or its revisions, and the contract specification.
2 Calibration procedures shall be provided, including the permitted tolerances for the
equipment to remain in service. The quality plan shall state the required accuracy of all plant
calibrations and shall identify any that require traceability to national reference standards (e.g.
mass or weight).
3 The plant shall be maintained to ensure that it continues to be capable of producing asphalt
to the required specifications and tolerances. Table A-2 gives guidance with regard to
schedules for calibration and checks.
4 The FPC quality plan documentation shall identify those items and areas of the plant where
constant use and wear will affect the quality of production including, but not limited to, the
dryer drum, hot elevator, screen deck and meshes, hot bins, weighing and mixing apparatus,
and state the inspection and maintenance schedules for these items in order to maintain
them to the condition necessary to ensure the quality of production.
5 A maintenance schedule shall be available and maintenance records shall be kept.
7.3.6 Plant Quality Control Laboratory
1 The asphalt plant shall have a quality control testing laboratory capable of conducting the
following tests:
(a) Sieve analysis (ASTM C117, C136, and D5444).

(b) Specific gravity for coarse and fine aggregates (ASTM C127, C128).
(c) Theoretical maximum specific gravity and density of asphalt mixtures (ASTM D2041).
(d) Quantitative extraction of asphalt binder from asphalt mixtures (ASTM D2172).
(e) Bulk specific gravity and density of compacted asphalt mixtures (ASTM D1188,
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D2726).
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2 The asphalt plant laboratory shall have the following:
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(a) Efficient quality management system.
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(b) Qualified laboratory manager.
(c) Qualified technicians.
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(d) Calibrated equipment.
3 The asphalt plant laboratory shall have a database includes but not limited to the following:
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(a) Production data.

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(b) Testing data.

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(c) Materials type and materials traceability to source data.

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4 The plant laboratory shall keep records of materials and asphalt mixtures properties on a
daily basis.
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5 The laboratory shall maintain a position description for each technical operational position
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shown on the laboratory’s organization chart. Position descriptions shall identify the position
and include a description of the duties, required skills, and education and experience
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associated with the position.

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6 The laboratory shall maintain technical staff training records, qualifications, work experience,
licensure, certifications, and current position for each supervisory technical staff member.
7 The laboratory shall maintain a procedure which describes the methods used for laboratory
personnel training to perform tests in accordance with standard procedures. Records of
laboratory personnel training shall be maintained.
8 The laboratory shall maintain a procedure describing the method used to evaluate staff
competency to ensure that each test covered by the scope of this standard is performed in
accordance with standard procedures. This description shall include the frequency of
competency evaluations for each technician and indicate what position or employee is
responsible for evaluating staff competency and maintaining records. The procedure shall
ensure that each technician receives a performance evaluation for each test that technician
performs.
9 The laboratory shall calibrate, standardize, and check all significant equipment associated
with tests which the laboratory performs.
10 The laboratory shall have a procedure for the storage, retention, and disposal of test
samples.
7.4 INSPECTION AND TESTING
7.4.1 General
1 All necessary facilities, equipment and personnel shall be available to carry out the required
inspections and tests.
2 Inspection and testing shall be carried out at least as frequently as indicated in Tables A-3 to
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A-7. Sampling shall be randomised so as not to introduce undue bias in the assessment of
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compliance. Due care shall be taken to adequately cover both large and small volumes of
material.
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3 At least 10% of quality control tests related to constituent materials and finished mixtures
shall be carried out by an approved thirty party laboratory. Third party testing schedule shall
be liaised with the Engineer.
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4 The results of all tests carried out on materials shall be recorded. Tests taken specifically for
the resolution of problems arising from process control shall be kept separately and need not
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be used for the purpose of calculating compliance with the technical specifications.
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5 All sampling and testing shall be carried out in accordance with the relevant standard
procedures required by the specification.
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7.4.2 Incoming constituent materials

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1 Incoming constituent materials shall be inspected and tested using procedures detailed in the
quality plan and to a schedule complying with this clause and the requirements of QCS 2014,
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or its revisions, and the contract specification.

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2 The required inspections of materials in storage shall be maintained to establish that no

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deterioration has occurred.

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3 Detailed requirements shall be as follows:
(a) Aggregates: see Table A-3.

(b) Filler: see Table A-4.
(c) Additive: see Table A-5.
(d) Binders: see Table A-6.
(e) Finished Asphalt Mixture: see Appendix “B”.
7.4.3 Finished Asphalt Mixture
1 The finished asphalt mixture shall be inspected and tested using procedures detailed in the
quality management system documentation and to a schedule complying with the
requirements of QCS 2014 and the contract specification.
2 Appropriate statistical records shall be maintained in order to monitor and verify process
capability and product characteristics.
3 Individual batch readings shall be recorded as part of the quality records. The plant
pyrometer shall be calibrated in accordance with ASTM E2847 and checked daily against a
calibrated laboratory thermometer, the record of which shall be maintained in the plant
control cabin/office. The temperature of the finished asphalt shall be the average load
temperature however no batch or part of the load shall exceed the maximum JSM
temperature for the mix. Measurement shall be in accordance with QCS 2014.
4 As a regular audit check on the efficacy of the plant quality control laboratory, 10% of
samples analysed for mix composition by the plant control laboratory shall have a duplicate
sample analysed in an independent laboratory, which is ISO17025 accredited in related tests.
The duplicate sampling may be done simultaneously as part of the Organization’s other
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testing obligations conducted by an approved independent laboratory. The duplicate results
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shall be regularly reviewed and any differences falling outside the reproducibility limits
published in the test standard applicable to the ASTM test methods employed shall be
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investigated.
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5 The results of all tests carried out on materials shall be recorded. Tests taken specifically for
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the resolution of problems arising from process control shall be kept separately and need not
be used for the purpose of calculating compliance with the technical specifications.
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6 All sampling and testing shall be carried out in accordance with the relevant standard
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procedures required by the specification.

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7 Sampling frequencies, operating compliance level (OCL) and test frequencies are provided in
Appendix “B”.
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7.5 NON-CONFORMITY
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7.5.1 General
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1 The producer shall establish and maintain documented procedures to ensure that constituent
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materials or asphalt mixture which when identified by in-process inspection does not conform
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to specified requirements is prevented from use or installation. This control shall provide for
identification, evaluation, separation from conforming product (when practical) and disposal
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of the nonconforming material or asphalt mixture.
2 The non-conformance process shall include:
(a) Constituent materials upon arrival at the plant or storage site.

(b) Constituent materials in storage.
(c) The manufacturing process.
(d) Handling, storage and delivery of the finished product.
7.5.2 Non-conformity of Material or Asphalt Mixtures
1 Where non-conforming constituent materials or finished asphalt mixtures are identified, the
cause of the non-conformance shall be investigated and identified to effect appropriate
corrective actions to prevent a reoccurrence. Such corrective actions shall be incorporated
into the FPC quality plan.
2 Corrective actions may involve reworking the material, adjusting the process, redirection to
another use where it may be acceptable, recycling for further use or rejection and disposal.
3 The FPC quality plan shall identify the action to be taken in process control when non-
conforming product is identified from analysis.
4 The FPC quality plan shall state the process under which the installation contractor and the
supervising agency will be notified of non-conforming analysis results.
7.6 INSPECTION, MEASURING AND TEST EQUIPMENT
1 The Organization shall control, calibrate and maintain suitable measuring and test equipment
as required by this guidance document and QCS 2014.
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2 To ensure the testing of incoming constituent materials and finished asphalt conforms to the
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relevant test method specification, the Organization, or where an independent laboratory is
employed by the Organization to conduct its quality control testing, shall ensure within the
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FPC quality plan that the measuring and test equipment used is maintained in a known state
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of calibration and maintenance.
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The equipment control procedures shall demonstrate the following:
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(a) Accuracy and frequency of calibration, which should be in accordance with the relevant
test standard.
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(b) Equipment is used in accordance with a documented procedure.

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(c) Equipment is uniquely identified.

(d) Calibration records to be maintained.
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7.7 PLANT GENERALLY

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1 The machinery and tools used in constructing the various items involved in asphalt works
shall be in good working condition and free of oil and fuel leaks. The Contractor shall
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maintain and preserve them for the whole duration of the work. The Engineer shall approve
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the machinery and tools before works begin and the Contractor shall supply adequate
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quantities of such machinery in order to execute the work with due speed and precision.
Equipment approved for use shall not be removed from the Site without the approval of the
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Engineer.
2 If required the Contractor shall furnish the Engineer with the manufacturer's catalogues,
specifications and other published data for the equipment and machinery he proposes to use.
3 On first erecting an asphalt plant and at least once each three months thereafter, the plant
shall be calibrated by a calibration service organisation approved by the LSA. Production
shall not be permitted if the weigh batch calibration does not comply with the requirements of
ASTM D995-95.
4 The Engineer shall have the right to stop the use of any equipment or plant which he deems
to be inferior to the quality required or detrimental to the permanent works and to instruct the
removal of such equipment and to have it replaced by suitable equipment.
5 The Contractor shall immediately comply with such instructions without being entitled to any
indemnities or extensions as a result of such instructions. The Contractor shall not be
allowed to use any equipment or plant before obtaining the approval of the Engineer, and the
Contractor shall undertake to follow sound technical methods in operation and to engage
skilled and trained operators, mechanics and labour to carry out the works. The Engineer
shall have the right to expel any operators, mechanics or labour and to instruct suitable
replacement thereof at any time he deems such action is necessary.
6 The Contractor shall comply with any special plant requirements published by the concerned
authority.
7.8 ASPHALT PLANT
7.8.1 General
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1 All plant used by the Contractor for the preparation of asphalt hot mixes shall be batch type
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plants conforming to the requirements as detailed below.
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2 The Engineer may permit the use of continuous drier drum type asphalt plants after a fully
detailed technical submission by the Contractor itemising the differences from the
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specification. In such cases after approval of the technical submission the Contractor shall
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carry out a full scale laying trial with testing of the hot and laid mix and monitoring of the plant
operation by the Engineers staff to assess the suitability of the proposed plant.
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3 No laboratory verification or plant trial shall be carried out by the LSA unless an automatic
compaction apparatus is available at the producer’s laboratory.
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7.8.2 Automatic Operation

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1 The plant shall be designed, co-ordinated and operated so as to continually produce an

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asphalt mix within the job mix tolerances specified.
2 The plant shall be equipped and operated so that the proportioning of the hot aggregate, filler
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and bitumen, together with the dry and wet mixing cycles are all controlled automatically.
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Positive interlock shall be provided so that proportioning, mixing and discharge are
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accomplished by one operation without manual control of the separate phase.

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3 The use of manual and semi-automatic plants for the production of asphalt is not permitted
unless specific approval is given in writing by the Engineer.
7.8.3 Cold Bins System
1 The plant shall include a sufficient number of cold storage bins so that there is at least one
bin for each different stockpile of material being used.
2 Intermixing of material from different stockpiles in one bin or on the ground before putting into
the bin is prohibited.
3 The cold bins and loading equipment used shall be compatible to prevent overflow between
the bins. Baffle plates shall also be used between bins to prevent overflow of one bin into
another. Each cold bin shall include an accurate means for continuously feeding the required
amount of mineral aggregate so that uniform production is achieved. The settings on the cold
bins shall be approved by the Engineer and shall be checked and calibrated as often as he
may deem necessary to ensure their continued accuracy. Change of settings shall be made
only with the approval of the Engineer.
7.8.4 Drier
1 A drier of satisfactory design shall be provided. The drier shall be capable of uniformly drying
and heating the aggregate to the moisture and temperature required without leaving any
visible burned oil or carbon residue on the aggregate when discharged from the drier.
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7.8.5 Dust Collector
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1 The plant shall be provided with a dust collector designed to waste, or to return all or part of
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the material collected to the asphalt plant.
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2 The asphalt plant shall have an efficient fugitive emission collection and control system to
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control dust or fume emissions from the drying, screening, weighing and mixing operations.
The collection system shall be so designed to prevent the emission of dust and fumes into
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the atmosphere in accordance with the environmental standards of Qatar.
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3 The collected dust from the drying process shall pass through a coarse collector which will
pass the coarse particles, substantially greater than 0.075mm, back to the hot elevator or to
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a silo for the controlled return to the asphalt mix. The reclaimed dust substantially less than
0.075mm shall be collected and passed into a storage silo for the controlled return as mineral
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filler to the asphalt mix through the filler weighbox or sent to waste.
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4 The plant shall be equipped with a filler silo for recovered filler. An additional dry storage silo
shall be provided for imported mineral filler with a provision of a separate weighing hopper to
proportion this filler into the mix.
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7.8.6 Screens
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1 Plant screens shall be capable of screening all aggregates to the specified sizes and
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proportions. They shall have capacities equal to or greater than the maximum rated capacity
of the plant. They shall have an operating efficiency such that the aggregate deposited in any
bins shall not contain more than 10 % oversize or undersize material. This screen tolerance
shall not invalidate the job mix tolerances specified.
7.8.7 Hot Bins
1 The plant shall include at least three storage bins for hot aggregate of sufficient size to supply
the pugmill when it is operating at full capacity. They shall be arranged to ensure separate
and adequate storage of appropriate fractions of the aggregate. Each compartment shall be
provided with an overflow pipe that shall be of such size and at such location as to prevent
any backing up of material into other bins or against the screens. Bins shall be so
constructed that samples can be readily obtained therefrom. The hot bins shall be equipped
with continuous level indicators to provide information about the level of each ingredient of
the JMF and to avoid shortage or overflow of aggregate from one bin to another.
7.8.8 Asphalt Binder Storage
1 Tanks for storage of asphalt binders shall be equipped for heating the material using positive
and automatic control at all times, to a temperature within the specified range. The heating
shall be accomplished by hot thermal oil, electricity or other approved means such that no
direct flame shall come in contact with the bitumen or heating tank.
2 The circulating system for the asphalt binder shall be of adequate size to ensure proper and
continuous circulation during the entire operating period. Suitable means shall be provided
either by double jacketed steam or hot oil or other insulation for maintaining the specified
temperature of the bituminous material in the pipeline, meters, weigh buckets, spray bars,
and other containers and flow lines.
3 The storage tank capacity shall be sufficient for at least one day's operation. Circulation
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return lines to the asphalt storage tanks should be submerged to the same elevation in the
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storage tanks as the feeder line. Two or three vertical slots may be cut in the return line
above the high level mark to break vacuum when reversing the pump.
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4 The Contractor shall provide a sampling outlet in the asphalt binder feed line connecting the
plant storage tanks to the asphalt binder weighing or metering box. The outlets shall consist
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of valves installed in such a manner that samples may be withdrawn slowly at any time during
plant operation. The locations of the sampling outlets shall be readily accessible and free
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from obstructions. Drainage receptacles shall be provided for flushing the outlets before
sampling.
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7.8.9 Thermometric Equipment

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1 An armoured thermometer reading from 38 C to 204 C shall be fixed in the bituminous feed
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line at a suitable location near the discharge valve. Similar devices shall be fixed in the
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heating and storage tanks.
2 The plant shall be further equipped with either an approved dial-scale, mercury-actuated
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thermometer, an electric pyrometer, or other approved thermometric instruments placed at

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the discharge chute of the drier and in the hot fines bin so as to register automatically or
indicate the temperature of the heated aggregates. For better regulation of the temperature
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of the aggregates, replacement of any thermometer by an approved temperature recording

apparatus may be required by the Engineer and he may further require that daily temperature
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charts be submitted to him by the Contractor.
7.8.10 Control of Mixing Time
1 The Plant shall be equipped with positive means to govern the time of mixing and to maintain
it constant unless changed at the direction of the Engineer.
7.8.11 Pugmill
1 The batch mixer shall be an approved twin pugmill type, capable of producing a uniform
mixture within the job-mix tolerances. It shall be so designed as to permit a visual inspection
of the mix. The mixer capacity shall be not less than 600 kg per batch and shall be so
constructed as to prevent leakage of contents.
2 The bitumen system shall deliver an even flow of binder into the mixer to ensure an even
distribution of bitumen binder throughout the mix during the wet mixing cycle.
3 The mixer shall be fully enclosed with sufficient air extraction to prevent emissions of dust
and fumes. The mixing cycle shall be controlled such that from charging of the mixer until the
closing of the mixer door at the completion of the cycle there shall be no leakage of
aggregate, filler or bitumen from the weighing hoppers. The system shall permit a dry mixing
period, defined as the interval of time between opening of the weigh box gate and the start of
application of bitumen, if required by the mixing process.
4 The wet mixing period is defined as the interval between the discharge of the bitumen binder
into the mixer and the mixer gate is opened to discharge the mix, and shall be not less than
30 seconds. The wet mix time shall be capable of being incrementally set at intervals of not
more than five seconds up to a wet mix time of three minutes. A mechanical batch counter
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shall register the completely mixed batches.
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5 The mixer shall be equipped with a full set of mixer paddles in a suitable arrangement, in
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accordance with the manufacturer’s specification, to produce a proper and uniformly mixed
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batch. All paddle arms and tips, and mixer liners shall be in good condition. Mixing shall
cease if any mixer arms or tips are missing, and shall not resume until replaced and
inspected.
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7.8.12 Temporary Storage of Mix
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1 Plants may be equipped with skips or elevators for delivering batched mix to hoppers or silos
before discharging to hauling units. The skips or elevators shall not be sprayed with diesel or
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other solvents; where necessary they may be sprayed with a minimum amount of lime water,
soap or detergent solution. Hoppers or silos shall be of such design that no segregation or
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loss in temperature of the mix occurs.

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7.8.13 Safety Requirements
1 Adequate and safe stairways to the mixer platform and guarded ladders to other plant units
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shall be placed at all points required for accessibility to all plant operations. Accessibility to
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the top of truck bodies shall be provided by means of a platform or other suitable device to
enable the Engineer to obtain mixture temperature data. To facilitate handling scale
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calibration equipment and sampling equipment, a hoist or pulley system shall be provided to
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raise or lower the equipment from the ground to platform or vice-versa. All gears, pulleys,
chains, sprockets and other dangerous moving parts shall be thoroughly guarded and
protected. Ample and unobstructed passage shall be maintained at all times in and around
the truck loading space. This space shall be kept free from drippings from the mixing
platform.
2 Accessibility to the top of loaded truck body shall be provided by means of a platform to
enable obtaining asphalt mixture samples and temperature readings and to check truck body
condition. All necessary safety measures shall be provided for accessing the top of loaded
truck body.
7.8.14 Weigh-Box
1 The plant shall include means for accurately weighing each size of aggregate in a weigh-box
or hopper, suspended on scales, ample in size to hold a full batch without hand raking or
running over.
2 The weigh-box or hopper shall be so constructed that they will not be thrown out of alignment
or adjustment. All edges, ends and sides of weighing hoppers shall be free from contact with
any supporting rods and columns or other equipment that will in any way affect the proper
functioning of the hopper.
3 There shall also be sufficient clearance between hoppers and supporting devices to prevent
accumulations of foreign materials. The discharge gate of the weigh-box shall be so hung
that the aggregate will not be segregated when dumped into the mixer and shall close tightly
when the hopper is empty so that no material is allowed to leak into the batch in the mixer
during the process of weighing the next batch.
4 Weighing boxes and hoppers shall be free hanging and placed on high precision load cells or
strain gauges.
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7.8.15 Scales or Meters
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1 Scales or meters used for proportioning aggregates, mineral filler and bitumen shall be
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accurate to 1 % of the indicated quantity. Scales and meters shall be substantially
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constructed. Scales and meters that require frequent adjustment shall be replaced. Scales
shall be constructed and located so as to prevent vibration in the dial pointer.
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Weighing sequence of hot aggregates shall progress from coarse to fine.
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3 Bituminous material shall be automatically proportioned by either weighing or metering. The
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minimum gradation shall be not more than 1 litre or 1 kg. Bituminous scales and weigh
buckets shall be such that the required amount of bitumen is provided in a single weighing
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and delivered to the pugmill without loss due to overflow, splashing or spillage.
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4 Bituminous weigh buckets shall be satisfactorily insulated to prevent loss of heat in the
bitumen or accumulation of bitumen in the bucket. Bituminous metering devices shall be
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rotating positive displacement pumps and shall be capable of providing the designated
quantity of material for each batch.
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5 All scales and meters shall be approved by the Engineer and shall be checked and calibrated
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as detailed in Clause 5.3. Production shall not be permitted if the weight batch calibration
does not comply with the requirements of ASTM D955-95.
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7.8.16 Plant Control System
1 The asphalt plant operations shall be fully automated and connected to a centralized control
system. Preferably, the plant operating software shall be capable to store the detailed
production history.
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APPENDIX “A”
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Table A-1: Process control minimum inspection schedule
Control Area Inspection/Test Purpose Minimum frequency

Identify
contamination,
Aggregate stockpiles As FPC quality plan Daily
intermingling, level
ground for tipping,
stock availability
Ensure correct
Cold feed bins As FPC quality plan feeding to plant and Weekly
maintenance of bins
Maintenance
inspection to ensure Monthly or as
Aggregate dryer As FPC quality plan FPC quality plan
effective heating and
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drying
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Dried Control for Continuously
Aggregate
heated conformance in production
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temperature
aggregate
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Identify mechanical Weekly or as
Aggregate screens As FPC quality plan
and physical defects FPC quality plan
As FPC quality plan nt

Identify mechanical
and physical defects
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Hot aggregate bins Weekly
Check screening
Hot bin gradations
efficacy
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Identify mechanical
and physical defect
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Weighing apparatus As FPC quality plan Check weighing Weekly

efficacy against truck
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scale
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Check storage
Tank temperature Daily
conformance
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Bitumen In accordance with

As FPC quality plan
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Binder properties storage

or in case of doubt
recommendations
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Temperature Test of To ascertain the

monitoring accuracy
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equipment is
equipment for comparison Weekly
functioning correctly
drying/heating and with calibrated
asphalt mix reference
process thermometer
Each batch or
Asphalt mix Mix temperature Ensure temperature
continuously in
conformance
production
Table A-2: Minimum plant calibration and check requirements
Item of Plant Inspection/Test Purpose Minimum frequency

To ensure that
Visual inspection as
weighing equipment is Daily
described in procedures
Weighing
equipment To ensure accuracy 1
a) on installation
Testing of weighing within quality plan b) every 3 months
accuracy - calibration requirements c) in case of doubt.
To ensure that
First batch of the day
dispenser is
Organoleptic* inspection containing admixture
Admixture/additive functioning correctly
dispensers To ensure accuracy 1
a) on installation
Test for accuracy as
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within quality plan b) every 3 months
described in procedures.
requirements c) in case of doubt.
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1
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Comparison of the actual To ensure accuracy a) on installation
Flow meters amount with the metered within quality plan b) every 3 months
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amount by reconciliation requirements c) in case of doubt.
Comparison of actual
mass of constituents in nt
To ensure the batching
a) on installation
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Batching system the batch with the accuracy in
b) every 3 months
(on batch plants) intended mass using the accordance with the
c) in case of doubt.
method prescribed in the quality plan
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quality plan
Comparison of actual
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mass in a measured To ensure the 1

a) on installation
Proportioning period of time with the accuracy in
b) every 12 months
system (cold feed) intended mass using the accordance with the
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c) in case of doubt.
method prescribed in the quality plan
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quality plan
To ensure the
Visual as described in
equipment is Daily
procedures
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Temperature
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Test of accuracy To ensure the

monitoring
comparison with equipment is Weekly
equipment
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calibrated reference functioning correctly

(infrared
thermometer 1
pyrometer)
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To ensure correct a) on installation

Test of accuracy - temperatures are b) every 12 months
calibration recorded c) in case of doubt.
Temperature To ensure the

Visual as described in
monitoring equipment is Daily
procedures
equipment (contact functioning correctly
probe or 1
thermocouple for To ensure correct a) on installation
drying heating Test of accuracy - temperatures are b) every 3 months
process) calibration recorded c) in case of doubt.
Table A-3: FPC Inspection and test guidance for aggregate stockpiles
Inspection/Test Purpose Minimum frequency
To check suitability for As required by QCS 2014,

Tests for aggregate properties
intended use or its revisions
Each size: Weekly

Tests for aggregate consistency To check consignment quality Each consignment: in
by sieve analysis case of doubt
To check consignment is
Inspection of delivery ticket as ordered and from Each delivery
correct source
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Table A-4: FPC inspection and test guidance for Filler
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Tests for filler properties To check suitability As required by QCS 2014,
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for intended use or its subsequent revisions
Tests for filler consistency To check consignment

or production quality nt Gradation: Weekly
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Plasticity: Weekly
Filler: Non plastic
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Appropriate tests to To confirm characteristics Each delivery or weekly

determine specified of product or check for reclaimed filler dust
properties compliance with
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specification
Inspection of delivery ticket To check consignment is Each delivery
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as ordered and from

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correct source
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Table A-5: FPC inspection and test guidance for additives

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Appropriate tests to To confirm characteristics a) Source approval prior

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determine intrinsic of product or check to initial use and

properties compliance with b) as stated in the quality plan
specification
Inspection of delivery ticket To check that consignment Each delivery
is as ordered and from the
correct source
Organoleptic* For comparison with Each delivery, if

check of normal appearance practicable; otherwise in
consignment accordance with quality
plan.
Table A-6: FPC Inspection and test guidance for bitumen binder

Tests for bitumen properties To check suitability for As required by QCS 2014 and
intended use project particular specification
Inspection of delivery ticket To check consignment is as Each delivery or production batch

ordered and from the correct
source
Temperature To check that binder is within (a) Each delivery or production
specified temperature limits batch
(b) Each tank recorded daily
Grade Properties (60/70) To assess compliance with 1 per 450 tons of binder delivered
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specification in normal production
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Grade Properties (PG76- 10) To assess compliance with 1 per 450 tons of binder delivered
specification in normal production
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Prior to production if stored for
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more than 3 days without further
deliveries or production batches
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Organoleptic* Check For comparison with normal Each delivery or daily survey of
perceptible properties tanks
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Table A-7: FPC minimum inspection/test frequencies for product quality control
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Organoleptic* check on For comparison with normal Every load

mixed asphalt appearance with regard to
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grading, evenness of mixing

and adequacy of binder
coating
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Suitability of delivery To check adequacy of a) Prior to first use

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vehicles by visual insulation b) In case of doubt.

assessment
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Cleanliness of delivery To avoid contamination Every load prior to loading

vehicles by visual To control use of release agent
assessment
Mixed asphalt temperature To assess conformity a) As required under Table

1
b) Whenever samples
are taken
Grading and binder content To assess conformity In accordance with QCS
2014
Other characteristics included To assess conformity In accordance with QCS
in technical specifications 2014
* Organoleptic check: a broader evaluation made with the senses: sight, touch, smell, hearing etc. rather
than a visual inspection.
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APPENDIX “B”
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MINIMUM SAMPLING FREQUENCIES AND TOLERANCES FOR THE FACTORY PRODUCTION

QUALITY CONTROL OF FINISHED ASPHALT
General
1 This Appendix includes sampling frequencies and tolerances for mixture composition for use
in the evaluation of conformity of mixed asphalt during production. It is consistent with QCS
2014 but is specifically intended as guidance for the Organization (Asphalt Producer) to
maintain the quality control of the finished asphalt mixture at the point of manufacture and
does not impede on the requirements of QCS 2014, or its revisions, or the contract
specification. The sampling and frequencies are the minimum that should be considered for
control but it is to discretion of the Organization to ensure sufficient samples, tests and
assessments are made in order for the asphalt mixture conforms to specification
requirements.
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2 The properties of asphalt mix characteristics shall conform to the requirements of QCS 2014
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and the contract specification. Should these not properties be found not to conform to the Job
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Mix Formula the design should be assessed.
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3 The guidance provides for three levels of minimum frequency. The minimum frequency which
shall be carried out for all production circumstances and higher frequencies which are
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appropriate where it is necessary to give a greater assurance of consistency where the
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measured level of conformity has decreased.
4 A guide to assessment of production quality control test conformity is given.

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Testing tolerances and conformity assessment

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1 Asphalt mixture composition Job Mix Tolerances shall be in accordance with QCS 2014, as
indicated in Table B.1:
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Table B.1: Job Mix Tolerances

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Intermediate
Description Base Course Wearing Courses
Course
a
Aggregate retained on 4.75mm

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±5% ±4% ±4%

sieve or larger
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Aggregate passing 4.75mm sieve

±4% ±3% ±3%
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Aggregate passing 850m sieve

 3%  2%  2%
Aggregate passing 75μm sieve ± 1.5 % ± 1.0 % ± 1.0 %
Binder Content ± 0.3 % ± 0.2 % ± 0.2 %
Operating Compliance Level
1 The Operating Compliance Level (OCL) shall be applicable to each single plant and shall be
determined on an ongoing basis from the number of non-conforming compositional test
results within the last 32 analyses of all asphalt mixtures tested. In addition, the OCL shall
take into account the consistency of production with assessment of the mean deviation from
target as detailed in Table B.2.
2 In the event of 5 or more of the previous 32 results being non-conforming, and/or variance of
the mean deviation from target from the prescribed tolerances, the plant shall be subject to
an immediate and comprehensive review of equipment and procedures.
Mean Deviation from Target
1 For each analysis the deviation from target shall be determined for each of the sieves sizes
and binder content indicated in Table B.1. A running mean of the deviations for the last 32
analyses of each asphalt mixture shall be maintained.
2 Should the running mean of the deviations exceed the values stated in Table B.2, this shall
be deemed to be non-conforming asphalt mixture in accordance with Clause 25.4.2 and the
appropriate corrective quality control action taken. The Operating Compliance Level shall be
lowered by one level for as long as the mean deviation stays outside tolerance.
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Table B.2: Mean deviation from target tolerances
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Description Base Course Intermediate Wearing Course
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Course
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Aggregate passing 19 mm ±4 ±3 -
Aggregate passing 12.5 mm - ±3
Aggregate passing 9.5 mm ±4 nt ±3 ±3
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Aggregate passing 4.75 mm
±3 ±2 ±2
(Superpave)
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Aggregate passing 2.36 mm

±3 ±2 ±2
(Marshall)
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Aggregate passing 75 μm sieve ± 1.5 ± 1.0 ± 1.0

Soluble Binder Content ± 0.3 ± 0.2 ± 0.2
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Test Frequency
1 The frequency for sampling shall be determined weekly and shall be maintained at the
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operating compliance level minimum frequency indicated in Table B.3.

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Table B.3: Determination of Operating Compliance Level and Sampling Frequency

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Number of nonconforming Operating Compliance

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Minimum Sample Frequency

analyses in last 32 Level
0-2 A 1 per 250t per mix or part thereof
3-6 B 1 per 200t per mix or part thereof
≥6 C 1 per 100t per mix or part thereof
2 New plants commencing production, plants restarting after relocating, a major repair or
overhaul, or those recommencing commercial production after a period exceeding 3 months
cessation shall operate under OCL until 32 results have accumulated after which the
frequency shall revert to the OCL achieved.
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APPENDIX “C”
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Table C-1: Sample of plant inspection checklist
Aggregate Stockpiles Yes No

Are aggregate stockpiles separated by walls or clear space
1 with signed labelling?
Are the stockpiles free of significant contamination and
2 segregation? (Plant drain-out aggregate is acceptable if the
aggregate size is similar and uncoated.)
Is the aggregate in good condition with no signs of degradation
3 on the stockpile due to vehicle/plant movements?
Is the truck tipping area at the stockpile level? (Non-level

4 surfaces can cause trucks to tip over.)
Do the aggregate delivery and test records conform to the
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5 approved mix designs?
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Have the aggregates been sampled and tested in accordance
6 with requirements?
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Aggregate Cold Feed
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Has each aggregate size its own designated and labelled
1 bin/hopper?
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Are bins/hoppers in good condition with no holes, with bin wall
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2 divider plates between each?
Is aggregate overflow between hoppers being prevented by
3 divider plates?
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If meshes (grizzlies) are fitted over the bins/hoppers, are they

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in reasonable condition and fit for purpose?

Are the feeder gates, feeder belts and vibrators in good
5 condition?
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Are there no-flow paddles/sensors on each feeder and are

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6 they working?
7 Date of the last feeder calibrations:
Is the aggregate collecting conveyor in good condition, with no
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8 holes or splits, or evidence of tracking (side movement) and

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the belt scrapers are in good order?

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Dryer
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Is there any significant aggregate spillage under the dryer

1 conveyor, the dryer drum or around the base of the hot
elevator?
Are the dryer lifters and flights are in good condition without
2 undue bending or deformation and none missing. (when dryer
is cold and stopped)
Is the drum exit chute temperature pyrometer, thermocouple
3 or probe clean, working and in calibration?
4 Date of last pyrometer, thermocouple or probe calibration:
Has the drum exit chute Date:
temperature equipment been
checked recently with a Drum chute: °C
5 referenced laboratory probe?
Laboratory probe:
°C
Dust Collection
Does the pre-skimmer or knockout box return the collected
1 fine sand to the plant hot elevator?
a: returned to a silo for re-use?
Is the bag house b: directly fed back into the asphalt

2
extracted dust:- plant?
c: wasted?
Does the laboratory monitor the gradation of the coarse pre-
3 skimmer or knockout box fines and bag house filler?
4 Is there a dust emission monitoring system on the plant?
5 Date of last certified plant stack emission test?
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Is the plant stack emission is visually clean with no obvious
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dust or smoke??
Aggregate Screening
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1 Is there any spillage around the screen deck area?
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2 Did the last screen inspection indicate any defects?
3 Date of last screen deck inspection:
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Are there any signs of damage or wear, especially adjacent to
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4 screen bearings or shafts?
Is there any significant dust emission from the screen housing
5 lids, covers or doors?
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Is there any evidence of holes, splits or tears in the screen

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6 meshes and is there any apparent and significant pegging or

blockages?
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Are there any loose screen meshes that need tightening or

7 support bars that are loose and need welding?
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Is there evidence of side seal seepage which could

8 contaminate screened aggregate or wear other parts?
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Hot Aggregate Bins

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Is there any indication of hot bin oversize or undersize in hot

1 bin drain-outs?
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2 Bin 1 Aggregate size 0 / X mm

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3 Bin 2 Aggregate size X / X mm

Are the individual hot stone bin overflow chutes/pipes blocked
8 or damaged?
Are there holes or damaged seams or welds in the hot bin
walls, especially in the corners and in the lower half of the
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bins?
Do the hot stone bin doors stick or seize? Is there evidence of

holes in or leakage from the doors?
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Weighing and Measuring Apparatus

Are the calibrations of the aggregate, filler and bitumen
1 weighing apparatus current and in date?
2 Aggregate weighing apparatus calibration date:
3 Bitumen weighing apparatus calibration date:
4 Filler weighing apparatus calibration date:
5 Mixed asphalt pyrometer calibration date:

Date:
Has the mixed asphalt pyrometer been
6 checked recently with a referenced Pyrometer: °C
laboratory probe? Laboratory probe: °C
Weighing efficacy:
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Do the printed batch weights equal the weight indicators and
are total load batch weights similar to the truck scale net
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weight?
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Does the bitumen bucket/kettle pass the static load test?
(Hold a fully weighed batch of bitumen for at least 30 seconds
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2 and note any change in weight. Repeat when empty and note
any major change in tare)
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Does the aggregate and filler weighing apparatus pass the
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3 static load test?
Is there any bitumen seepage or leakage from the charge and
the discharge pipes, and the butterfly valve underneath on
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direct gravity discharge bitumen bucket/kettle systems?
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Is the bitumen bucket/kettle adequately insulated and heated?

Seepage or leakage from the charge and the discharge
5 pipes? Check the butterfly valve underneath for direct gravity
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discharge systems.
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Bitumen Storage and Pumping

Where fitted, are breather vents clear on the bitumen weigh
1 bucket/kettle and delivery pipe to the mixer?
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Are the bitumen tanks and are all tanks clearly labelled
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2 according to the grade of binder stored?

Are stored binder tank temperatures compliant with
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3 specification or supplier recommendations?

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Where PMB is stored, are the stirrers operational and in good

4 condition?
Is there a supplier defined procedure for the storage and use
5 of polymer modified binders?
Are all tanks, pipes, pumps and flow meters properly
6 insulated and the surrounds clean and in good order?
Is there any evidence of excessive bitumen or oil
7 seepage/leaks from pump(s), valves or manifolds?
Are bitumen tank temperatures monitored and recorded daily
8 by the plant staff?
Are the bitumen binders tested for foaming when heated to
9 175°C?
Is there a control or procedure for tank/binder grade selection
10 according to asphalt mix recipe to avoid using the incorrect
grade?
Asphalt Mixing
Are the weighing apparatus and mixer external surrounds in
1 clean and good order with no apparent seepage or leakage of
aggregate, filler or bitumen?
Are inspection hatches secure and sealed to prevent dust
2 emission?
Are electric cables, hydraulic and air lines well maintained and
3 in good order?
Are all mixer arms, paddles and tips, liners and door seals
4 present and in good condition?
Is the aggregate weighing sequence, coarse size to fine size?
5
Is there excessive overflow from the aggregate overflow
6 chutes?
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7 Check the required batch weights on the mix card.
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Are batch deviations within acceptable guide tolerance?
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9 Batch aggregate component ±1.5% of total batch weight
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10 Bitumen deviation ±0.1% of total batch weight
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Mineral filler deviations ±0.1% of total batch weight
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Are the in-flight adjustments being made automatically by the
12 plant control system?
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13 What is the delay time after aggregate discharge for bitumen: sec.
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14 What is the delay time after aggregate discharge for filler: sec.
What is the total wet mixing time in seconds?
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(From the complete discharge of the bitumen and filler to the

15 sec.
emptying of the finished batch)
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On completion of the mixing cycle, does the mixer fully

16 empty?
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On visually inspecting single batches of asphalt, is the

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17 appearance consistent from side to side and front to back,

and not segregated?
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Does each batch conform to the mix temperature

18 specification requirement?
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Does the plant indicated mixed asphalt temperature

19 correspond with a laboratory check?
Where used, is the skip hopper acceptably clean?
20
Are the empty hot storage silos acceptably clean without cold
21 asphalt sticking to the sides and corners?
Loading
Are all trucks acceptably clean prior to loading without any
1 evidence of diesel being used as a release agent?
Are all trucks equipped with load cover sheets or canvasses?

2
Are the loaded trucks free of significant segregation?
3
Is the asphalt temperature acceptably consistent and within

4 range tolerance throughout the load front to back?
Has the correct delivery ticket been issued to the driver with
5 accurate asphalt description, truck reference or number, site
address, driver name, and ticket number?
Is the plant sampling technician equipped with all necessary
PPE including safety helmet, steel-capped boots, overalls,
6 gloves, hi-visibility jacket, and protective eye glasses?
Are the plants sampling procedures being following by the

7 technician to ensure a representative sample?
(Ask for and retain a copy of the sampling procedures.)
Are plant sample details, including truck delivery details, are

8 recorded on each plant sample?
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Request plant compliance rate for each product supplied to the
9 project or contract for record purposes.
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END OF PART
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Part 08: Recycled and Stabilised Road Materials
8 RECYCLED AND STABILISED ROAD MATERIALS ............................................................ 2

8.1 GENERAL 2
8.1.1 SCOPE 2
8.1.2 REFERENCES 2
8.1.3 DEFINITIONS 3
8.1.4 SUBMITTALS 4
8.1.5 QUALITY ASSURANCE 4
8.2 COLD STABILISED MATERIAL - GENERAL 4
8.3 MATERIALS 5
8.4 CEMENT TREATED BASE (CTB) 6
8.4.1 PREPARATION AND MIX DESIGN FOR CEMENT TREATED BASE 6
8.4.2 SITE TRIALS FOR CEMENT TREATED BASE AND BITUMEN STABILISED MATERIAL 7
8.4.3 INSITU STABILISATION AND COMPACTION OF CEMENT TREATED BASE 7
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8.4.4 EXSITU PRODUCTION OF CEMENT TREATED BASE 9
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8.4.5 LAYING AND COMPACTION OF CEMENT TREATED BASE 9
8.4.6 JOINTS IN CEMENT TREATED BASE 10
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8.4.7 SAMPLING AND TESTING - CEMENT TREATED BASE 10
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8.4.8 EVENNESS AND LEVEL 12
8.5 BITUMEN STABILISED MATERIAL (BSM) 12
8.5.1
8.5.2
PREPARATION AND MIX DESIGN FOR BITUMEN STABILISED MATERIAL
SITE TRIALS FOR BITUMEN STABILISED MATERIAL
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8.5.3 INSITU STABILISATION AND COMPACTION OF BITUMEN STABILISED MATERIAL 13
8.5.4 EXSITU PRODUCTION OF BITUMEN STABILISED MATERIAL 14
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8.5.5 LAYING AND COMPACTION OF BITUMEN STABILISED MATERIAL 15

8.5.6 JOINTS IN BITUMEN STABILISED MATERIAL 16
8.5.7 SAMPLING AND TESTING - BITUMEN STABILISED MATERIAL 16
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8.5.8 EVENNESS AND LEVEL 17

8.6 DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN
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(EXPANSION RATIO AND HALF LIFE) 18

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8.6.1 SCOPE 18
8.6.2 DEFINITIONS 18
8.6.3 APPARATUS 18
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8.6.4 METHOD 19
8.6.5 REPORTING 19
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8.6.6 SITE QUALITY CONTROL 20

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APPENDIX ............................................................................................................................................ 21
GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)
8 RECYCLED AND STABILISED ROAD MATERIALS

8.1 GENERAL
8.1.1 Scope
1 This Part includes materials, equipment, mix design guidelines and other requirements for
the construction of insitu and exsitu recycled pavement layers.
2 Incorporation of stabilized or cement bound materials in pavement layers shall be based on

pavement structural design criteria such as layer(s) strength characteristics, load distribution,
layer(s) thickness equivalency, layers strength balance and the target level of pavement
performance.
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3 Use of recycled and stabilized materials and their associated construction and quality
assurance and quality control processes shall be approved by the Engineer.
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Section 6 Part 1 General
Part 3 Earthworks
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Section 5
Part 4 Water
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8.1.2 References
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AASHTO T180: ..........Standard Method of Test for Moisture-Density Relations of Soils

ASTM C150: ..............Standard Specification for Portland Cement
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ASTM C977: ..............Standard Specification for Quicklime and Hydrated Lime for Soil
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Stabilization
ASTM C1097: ............Standard Specification for Hydrated Lime for Use in Asphalt Cement
or Bituminous Pavements
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ASTM D422: ..............Standard Test Method for Particle-Size Analysis of Soils

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ASTM D946: ..............Standard Specification for Penetration-Graded Asphalt Cement for

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Use in Pavement Construction

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ASTM D1556: ............Standard Test Method for Density and Unit Weight of Soil in Place by
Sand-Cone Method
ASTM D1632: ............Standard Practice for Making and Curing Soil-Cement Compression
and Flexure Test Specimens in the Laboratory
ASTM D1633: ............Standard Test Methods for Compressive Strength of Molded Soil-
Cement Cylinders
ASTM D2216: ............Standard Test Methods for Laboratory Determination of Water
(Moisture) Content of Soil and Rock by Mass
ASTM D2922: ............Standard Test Methods for Density of Soil and Soil Aggregate in Place
by Nuclear Methods (Shallow Depth)
ASTM D4215: ............Standard Specification for Cold-Mixed, Cold-Laid Bituminous Paving
Mixtures
ASTM D4318: ............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4944: .............Standard Test Method for Field Determination of Water (Moisture)
ASTM D4944: ............Standard Test Method for Field Determination of Water (Moisture)
ASTM D6926: ............Standard Practice for Preparation of Bituminous Specimens Using
Marshall Apparatus
ASTM D6931: ............Standard Test Method for Indirect Tensile (IDT) Strength of
Bituminous Mixtures
ASTM D6938: ............Standard Test Method for In-Place Density and Water Content of Soil
ASTM D7382: ............Standard Test Methods for Determination of Maximum Dry Unit
Weight and Water Content Range for Effective Compaction of
Granular Soils Using a Vibrating Hammer
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ASTM E2583: ............Standard Test Method for Measuring Deflections with a Light Weight
Deflectometer (LWD)
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MCHW Specification for Highways Works Series 900, UK
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TG2 Technical Guideline: Bitumen Stabilised Materials: Asphalt Academy, South Africa
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TRL 611: A Guide to the Use and Specification of Cold Recycled Materials
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8.1.3 Definitions
1 Stabilisation is the permanent modification of soils and aggregates, including recycling

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existing pavements, to enhance the engineering properties thereby improving the load
bearing capacity and performance of a new pavement structure.
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2 Aggregate: Granular material used in construction. Aggregate may be natural, manufactured

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or recycled.
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3 Primary Aggregate: aggregate extracted directly from the ground in quarries or pits, or
dredged from rivers or the sea. They can be either hard rock such as gabbro and limestone,
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or sand and gravel.

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4 Secondary Aggregate: materials produced as a by-product of other mining or quarrying

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activities or as a by-product of other industrial processes, e.g. blast furnace slag, incinerator
ash, or the ash from power stations.
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5 Recycled Aggregate: materials produced by the recycling of construction and demolition

waste. These can be crushed concrete, bricks or glass, asphalt planings (i.e. the asphalt
layers of roads removed during roadworks, also known as RAP – Recycled Asphalt
Pavement).
6 Cold Stabilised Material (CSM): materials produced for pavement construction structural
layers using recycled or secondary aggregates.
7 Bitumen Stabilised Material (BSM): granular aggregate materials bound with foamed
bitumen or bitumen emulsions.
8 Cement Treated Base (CTB): granular aggregate materials bound with cement or hydrated
lime hydraulic binder.
9 Exsitu Stabilisation: mixing processes that are carried out away from the construction
location in a remote mixing plant.
10 Insitu Stabilisation: mixing processes that are carried out at the construction location by
specialised stabilisation equipment.
11 Optimum Moisture Content: the moisture content of soil at which a specific degree of
compaction will produce the maximum dry density when determined in accordance with the
AASHTO T180.
12 Maximum Dry Density: the dry density of soil obtained using a specific degree of compaction
at the optimum moisture content when determined in accordance with AASHTO T180.
8.1.4 Submittals
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1 The Contractor shall submit recent test results for the proposed sources of materials for all
quality requirements of the Contract. The contractor shall submit a test certificate that proves
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that the raw materials that are purchased/used comply with specifications. The testing may
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be performed by an approved private laboratory or by the laboratory associated with the
plant itself.
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The contractor shall submit to the Engineer for approval method statements, which includes
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but not limited to the following:
(a) Quality assurance and quality control plans of all construction activities
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(b) Material, handling, storage, identification and marking, traceability to source of

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production and testing.

(c) Equipment suitability to fulfil all construction activities to the required quality
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(d) Personnel capability

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(e) Safety and environment preservation plans

3 The Contractor will be required to produce detailed method statements for the chosen
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method of recycling rehabilitation and shall include all stages of the process for approval by
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the Engineer. This shall include the credentials and details of experience of the stabilising
contractor, the site investigation report, the stabilised material mix design and the equipment
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to be used for the entire process. A separate method statement shall be submitted for each
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of the production and construction activities of each layer.
1 If requested the Contractor shall arrange for the Engineer to visit the source of the materials
and jointly take samples for testing. The Contractor shall carry out testing as directed by the
Engineer.
8.2 COLD STABILISED MATERIAL - GENERAL
1 Cold Stabilised Material (CSM) comprises base and binder courses produced by the process
of in-place recycling (insitu) or in a fixed or mobile mixing plant (exsitu) where the aggregate
source shall be obtained by cold pulverisation of all, or part, of the existing road structure,
blended if necessary with other aggregate and bound with cementitious / hydraulic (CTB) or
bituminous binders (BSM), separately or in combination, or by the use of primary
aggregates.
2 Cold Stabilised Material (CSM) shall be designed and produced to form the foundation or
main structural layer of the road pavement.
3 For Bitumen Stabilised Material (BSM) the primary active binder (stabilising agent) shall be
foamed bitumen, with cement as an adhesion agent as required by the design. For Cement
Treated Base (CTB) the primary active binder shall be cement, hydrated lime or a blend of
both in accordance with the mix design. The aggregate grading may be adjusted by the
addition of inactive mineral filler.
4 Insitu and exsitu methods of stabilisation rehabilitation are permissible with the approval of
the Engineer on a site by site basis.
5 Stabilisation design and installation processes shall be in accordance with internationally

recognised standards and specifications, and shall meet the necessary pavement structural
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design according to the appropriate traffic classification.
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6 The Cold Stabilised Material shall be designed to achieve the specified level of the
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appropriate end performance property to the requirements of the total pavement design. The
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minimum layer thickness shall be as required by the design method used, as approved by
the Engineer.
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The asphalt type and thickness above the CSM shall be as required by the pavement design
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method and shall also be sufficient to prevent reflective cracking and early life trafficking, to
the satisfaction of the Engineer.
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8.3 MATERIALS
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1 The method statement submitted by Contractor shall contain details of all aggregates to be
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used in the CSM.

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2 Aggregates may include:

(a) Material planed or excavated from a road or other paved area.
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(b) Primary, secondary or recycled aggregate from other sources.

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(c) Mineral filler from primary or secondary sources.

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3 The aggregate including added inactive filler shall not contain deleterious material that
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adversely affects the performance of the mixture. This includes clay materials, friable
materials, organic and metallic materials, or other extraneous or detrimental material.
4 The aggregate gradation for CSM shall follow the requirements stated in the mix design
method, as approved by the Engineer, and shall generally follow the recommended
gradations in Table 8.1 Recommended Gradations for Cold Stabilised Materials.
5 For BSM, material passing the 0.425mm sieve shall have a maximum liquid limit of 25% and
the plasticity index shall not exceed 6.
6 Bitumen specified for use in BSM shall be 60/70 penetration grade in accordance with ASTM
D946 and shall only be obtained from approved sources. The temperature of the bitumen
prior to foaming shall be greater than 175°C but less than 195°C. Bitumen shall not contain
any additives which may suppress foaming.
Table 8.1 Recommended Gradations for Cold Stabilised Materials

Sieve Size Bitumen Stabilised Job Mix Control
Cement Treat Base (CTB)
(mm) Material (BSM) Sieve Tolerances
50 100 100 100 100 -2
37.5 85 100 87 100 ±5
25 72 100 77 100 -
19 60 100 67 99 ±8
12.5 50 100 67 90 -
9.5 42 90 48 80 ±8
6.3 35 80 40 62 -
4.75 30 72 35 56 ± 10
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2.36 21 56 25 42 -
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1.18 14 44 18 33 -
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0.6 9 35 14 28 ±5
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0.425 7 31 12 26 -
0.3 5 27 10
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0.15 2 21 7 17 -
0.075 2.0 18.0 4.0 10.0 ±3
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7 Cement specified for use in BSM and CTB shall be Portland cement in accordance with
ASTM C150 and shall only be obtained from approved sources. Sulfate resisting cement
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shall be used if instructed by the Engineer.

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8 Hydrated lime for use in BSM shall be in accordance with ASTM C1097 and for CTB shall be
in accordance with ASTM C977, and shall only be obtained from approved sources.
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9 Water for use in CSM shall in accordance with Section 5 Part 4.

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8.4 CEMENT TREATED BASE (CTB)

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8.4.1 Preparation And Mix Design For Cement Treated Base
1 The Contractor shall produce a detailed existing pavement investigation report and the
proposed stabilised material mix design which shall be submitted for approval by the
Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
commencement of the stabilisation works. The pavement investigation report shall consist of
cores and trial pits excavated to the existing subgrade and include tests for, but not limited
to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
liquid limit, and other tests required by the selected design method.
2 All equipment and method statements shall be submitted for approval by the Engineer at
least 30 days prior to commencement of works.
3 The mix design method for the CTB mix shall be as approved by the Engineer. Methods may
include that stated in this part, MCHW Specification for Highways Works Series 900: UK, or
other similar and equivalent recognised international design methods for cement or hydraulic
bound materials.
4 The CTB mix shall have a minimum individual 7 day compressive strength > 2.1 MPa with a
maximum average 7 day compressive strength of 4.2 MPa when tested in accordance with
ASTM D1633.
5 The mix design shall derive the gradation tolerance parameters of the pulverised material,
moisture content at the point of compaction and target flow rates for the active filler, binder
and added water at the point of mixing, appropriate to the production or stabilisation method
used for the approval of the Engineer.
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8.4.2 Site Trials For Cement Treated Base And Bitumen Stabilised Material
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1 The CTB mix design shall be subjected to full preliminary trials and testing at least 10 days
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prior to commencement of the full works and shall determine:
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(a) The effectiveness of the production and laying plant for exsitu processes;
(b)
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The number of passes of the stabilisation machine necessary to achieve uniform
pulverisation and mixing for insitu processes;
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(c) The field moisture content control required to achieve specified compaction
requirements;
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(d) The compaction routine and rolling patterns necessary to meet the specified
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compaction requirements;
(e) The reference density;
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(f) The effectiveness of the contractor’s inspection and test plan.

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2 The length of the trial section shall be at least 150 metres and the full width of the
carriageway proposed for stabilisation to ensure joints and full width compaction can be
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achieved without excessive segregation or other significant defects.

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3 The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2
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and allowed to cure for a minimum of 24 hours without trafficking unless otherwise
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authorised by the Engineer.
4 Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
to commencement of the works. No works may proceed until all tests and final method
statements have been submitted and approved by the Engineer.
5 Where materials and processes are demonstrably similar, mix designs and trials tests from
previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
Quality Standards.
8.4.3 Insitu Stabilisation And Compaction Of Cement Treated Base
1 The insitu CTB stabilisation/recycling shall be produced by specialist equipment specifically

designed for the purpose of insitu recycling processes.
2 The material shall be pulverised and stabilised in a single layer if its compacted thickness is
300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
the lower layer has achieved adequate stability before proceeding with the overlying layer.
3 Where required by the Engineer the stability of a layer in any area shall be assessed after a
curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
mean vertical deformations at the above trafficking increments shall be plotted against the
respective number of truck passes and the mean vertical deformation corresponding to 100
standard axles shall be interpolated. The layer shall be deemed acceptable if the mean
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vertical deformation corresponding to 100 standard axles is less than 10 mm.
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4 The active filler (cement/hydrated lime) shall be supplied to the recycler by a specifically
designed and calibrated mobile slurry mixer to ensure the dustless addition of the
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cement/hydraulic binder. The addition shall be continuously monitored with records taken to
confirm the target addition rate, ± 10%, according to the mix design.
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5 Mixing uniformity shall be continuously inspected visually by the contractor and work shall
stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
production process.
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6 Should either the slurry mixer supply to the mixer fail to operate or deliver the correct
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proportions to the recycler, all work shall cease until this has been corrected. Prior to
resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
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exceeding 50 metres to ensure the process is fully operational and under control.
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7 The recycler shall proceed in a continuous operation to the full depth of the layer being
recycled as required by the pavement design.
a
8 The CTB moisture content prior to compaction shall be within ± 2 % of the target determined
ar
during the mix design procedure to achieve maximum density.

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9 Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
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appropriate with the thickness of the layer being compacted. The vibration mode must be set
on high amplitude to achieve maximum penetration of compactive effort.
10 The rolling pattern should first concentrate on the middle section between the rear wheel
paths of the recycler, then across the full cut width to achieve uniform density. The travel
speed of the roller shall not exceed 3 km/h.
11 When initial compaction is complete, the surface shall be struck off to level by a grader and
the surface again checked for level and any defects or damage caused during the operation
which shall be corrected prior to final compaction.
12 Where the recycler has a screed finisher which achieves the required level, initial
compaction shall follow the recommendations of the recycler supplier.
13 Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
excessively over or under bindered, or watered.
14 Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
2
rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking
unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
2
applied at a rate of 5.5 to 7.0 kg/m .
15 Traffic, including delivery vehicles shall not be permitted on the uncompacted or semi-
compacted recycled material. The exposed longitudinal joint shall be protected from damage
by construction plant and vehicles.
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8.4.4 Exsitu Production Of Cement Treated Base
in
1 The exsitu production of CTB shall be produced by specialist recycling and stabilisation
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production equipment specifically designed for the purpose of exsitu processes.
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2 The active filler (cement/hydrated lime) shall be supplied to the mixer by specifically
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designed and calibrated weighing apparatus to ensure the correct addition of the
cement/hydraulic binder. The addition shall be continuously monitored with records taken to
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confirm the target addition rate, ± 10%, according to the mix design.
&
stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
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production process.
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4 CTB shall not segregate significantly during production and all measures shall be taken to
avoid this occurrence.
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5 CTB shall be conveyed from the mixer to its place in the Works as rapidly as possible in
covered vehicles which will prevent segregation or drying out and ensure that the material is
a
of the required workability and moisture content at the point of delivery to the paving
ar
equipment.
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6 Where CTB is produced on an exsitu production plant, the material shall be laid and fully
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compacted within 2 hours of production, ensuring that the moisture content is within the
required limits at the time of laying. CTB that exceeds 2 hours shall be rejected.
8.4.5 Laying And Compaction Of Cement Treated Base
1 Exsitu produced CTB materials shall be laid with paving machines and compaction plant as
detailed in Section 6 Part 5, but may include additional specialist equipment deemed
appropriate indicated in the detailed method statement.
2 The CTB moisture content prior to compaction shall be within ± 2 % of the target determined
3 Material shall be laid to a thickness that would result in layers not more than 150 mm thick
4 Final compaction for CTB shall follow the general requirements Section 6 Part 6 using a
combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
the approved method statement.
5 Where the surface of the recycled layer has been graded to level, it may be dampened with
a water spray prior to compaction. Care shall be taken not to use excessive watering.
7 Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
the requirements of Section 6 Part 5 shall be followed.
8 After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
g
in
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2
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2
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8.4.6 Joints In Cement Treated Base

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1 Transverse joints shall be made by cutting back at least 2 metres to the position of
conforming level and compaction, and cleaned to remove any loose material. The joint shall
di
be fully compacted and left level and smooth.

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2 Longitudinal joints shall be formed as follows:
3 For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of
a
the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to
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cross compaction. Joints are deemed to be fresh when the pavement materials on both
sides of the joint have been stabilised and are able to be compacted within 1 hour. The
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500mm partially compacted strip together with the exposed edge shall be lightly moistened
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prior to placement of the second strip.
4 For paver laid materials and where the stabilised layer has been laid previously or is deemed
unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to
remove any loose material prior to paving the new adjacent strip.
5 Longitudinal construction joints in CTB shall always be formed at the lane line marking
positions where practically possible.
8.4.7 Sampling And Testing - Cement Treated Base
1 The Contractor shall produce an inspection and test plan for the complete process which
shall include daily production control and the finished stabilised pavement for approval by the
Engineer.
2 Bulk samples shall be taken from the stabilised material to the full depth of the layer.
3 Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
protected from the heat and sun in an ambient temperature of no greater than 20°C.
4 Samples shall be provided from the laid CTB before compaction, as approved by the
Engineer. One group of five samples shall be provided from five locations equally spaced
along a diagonal that bisects each 800m2 or part thereof laid each day. The number of
groups may be increased if required by the Engineer. Each group shall be combined to
provide samples for reference density, compressive strength and laboratory determined
moisture content.
5 For each group, 3 specimens for reference density and compressive strength testing shall be
compacted in accordance with AASHTO T180within 2 hours of the addition of the cement
and cured in accordance with ASTM D1632, and tested in accordance with ASTM D1633.
6 To determine the reference density of test specimens the mould shall be weighed prior to
g
making the specimen and the mass recorded. Immediately after completion of compaction,
in
the specimen and mould shall be weighed and the mass recorded. These masses together
with the nominal volume of the mould shall be used to derive the reference density of the
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specimen.
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7 The in-situ density of a layer of cement bound material shall be taken as the average of the
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densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part
thereof laid each day. The in-situ density at each location shall be the average of two
co
readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
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8 Testing for CTB shall be required as Table 8. 2 Sampling and Testing Requirements for
Cement Treated Base
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Table 8. 2 Sampling and Testing Requirements for Cement Treated Base

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TEST METHOD SAMPLE POINT SPECIFICATION FREQUENCY
Sieve Pre-Stabilised Pulverised 3

ASTM D422 Design mix gradation 1/1000m
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Analysis Materials
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Pre-Stabilised Pulverised Less than design mix 3

Liquid Limit ASTM D4318 1/1000m
Materials determination
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Plasticity Pre-Stabilised Pulverised Less than design mix 3

ASTM D4318 1/1000m
Index Materials determination
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ASTM Compacted Stabilised 2

Field Density 100% reference density 5/800m
D1556/D6938 Material
Field
Pre-compacted Stabilised 2
Moisture ASTM D4944 ± 2% OMC 1/800m
Material
Content
Surface Compacted Stabilised 1 2
ASTM E2583 Report Values 5/800m
Modulus Material
Compressive Pre-compacted Stabilised Individual >2.1 MPa 2
ASTM D1633 1/800m
Strength Material Average of 3 <4.2 MPa
Reference Pre-compacted Stabilised 2
AASHTO T-180 - 1/800m
density Material
Moisture 2
ASTM D2216 Laid Stabilised Material ± 2% OMC 1/800m
Content
Note 1 – The surface modulus determined in accordance with ASTM E2583 shall be reported as
directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
criteria.
8.4.8 Evenness And Level
1 The transverse regularity of the surface of the CTB shall be tested by means of a 4 metre
long straight edge. No irregularity in excess of 10 mm shall be permitted.
2 The longitudinal regularity of the surface of the CTB shall be tested by means of a rolling
straight edge. No irregularity in excess of 10 mm shall be permitted.
the designated grade levels to within ± 10 mm.
reshaping by adding or removing material as necessary, adding water if necessary and
recompacting the layer. The minimum length of rectification shall be 50 metres.
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in
5 Acceptance of the stabilised pavement is subject to completion of all testing and inspection
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requirements to the satisfaction of the Engineer.
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8.5 BITUMEN STABILISED MATERIAL (BSM)
8.5.1
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Preparation And Mix Design For Bitumen Stabilised Material
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1 The Contractor shall produce a detailed existing pavement investigation report and the
proposed stabilised material mix design which shall be submitted for approval by the
Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
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commencement of the stabilisation works. The pavement investigation report shall consist of
cores and trial pits excavated to the existing subgrade and include tests for, but not limited
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to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
liquid limit, and other tests required by the selected design method.
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2 All equipment and method statements shall be submitted for approval by the Engineer at
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least 30 days prior to commencement of works.
3 The mix design method for the BSM mix shall be as approved by the Engineer. Methods
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may include that stated in this part, or MCHW Specification for Highways Works Series 900:
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(UK), or other similar and equivalent recognised international design methods for Bitumen
Stabilised Material.
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4 The aggregate gradation for BSM shall follow the guideline in Error! Reference source not
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ound. unless otherwise stated in the approved alternative design method.
5 The Design Mixture for BSM shall have minimum bitumen content of 2.5% with an active
filler content no greater than 1%, by mass of total mix.
6 The Binder Expansion Ratio (ER) shall be greater than 10 times and the Binder Half Life
(T½) greater than 12 seconds.
7 The Indirect Tensile Strength dry (ITSdry - 100mmØ specimens) shall be greater than 225
kPa and the Indirect Tensile Strength wet (ITSwet - 100mmØ specimens) shall be greater
than 100 kPa when tested in accordance with ASTM D6931. The Tensile Strength Ratio
(TSR) shall be greater than 80%
8 The Unconfined Compressive Strength of the mixture shall be between 1200 and 3500 kPa
when tested in accordance with ASTM D1633.
8.5.2 Site Trials For Bitumen Stabilised Material
1 The BSM mix design shall be subjected to full preliminary trials and testing at least 10 days
prior to commencement of the full works and shall determine:
(a) the effectiveness of the production and laying plant for exsitu processes;
(b) the number of passes of the stabilisation machine necessary to achieve uniform
pulverisation and mixing for insitu processes;
(c) the field moisture content control required to achieve specified compaction
requirements;
(d) the compaction routine and rolling patterns necessary to meet the specified
compaction requirements;
(e) the reference density;
(f) the effectiveness of the contractor’s inspection and test plan.
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in
2 The length of the trial section shall be at least 150 metres and the full width of the
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carriageway proposed for stabilisation to ensure joints and full width compaction can be
achieved without excessive segregation or other significant defects.
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2
3 The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m and
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allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by
the Engineer.
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4 Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
to commencement of the works. No works may proceed until all tests and final method
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statements have been submitted and approved by the Engineer.

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5 Where materials and processes are demonstrably similar, mix designs and trials tests from
previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
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Quality Standards.
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8.5.3 Insitu Stabilisation And Compaction Of Bitumen Stabilised Material
1 The insitu BSM stabilisation/recycling shall be produced by specialist equipment specifically

a
designed for the purpose of insitu recycling processes.

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2 The material shall be pulverised and stabilised in a single layer if its compacted thickness is
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300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
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thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
the lower layer has achieved adequate stability before proceeding with the overlying layer.
3 Where required by the Engineer the stability of a layer in any area shall be assessed after a
curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
mean vertical deformations at the above trafficking increments shall be plotted against the
respective number of truck passes and the mean vertical deformation corresponding to 100
standard axles shall be interpolated. The layer shall be deemed acceptable if the mean
vertical deformation corresponding to 100 standard axles is less than 10 mm.
4 The bitumen tanker shall a consistent flow of binder to the recycler. The addition shall be
continuously monitored with records taken to confirm the target addition rate, ± 10%,
according to the mix design.
5 The active filler (cement) shall be supplied to the recycler by a specifically designed and
calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder.
The addition shall be monitored with records taken to confirm the correct addition rate
according to the mix design.
stop when bitumen streaks or blotches are observed, or where cement is seen to
agglomerate or not fully mix in during the production process.
7 Should either the slurry mixer or the binder supply to the mixer fail to operate or deliver the
correct proportions to the recycler, all work shall cease until this has been corrected. Prior to
resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
exceeding 50 metres to ensure the process is fully operational and under control.
8 The recycler shall proceed in a continuous operation to the full depth of the layer being
recycled as required by the pavement design.
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9 The BSM moisture content prior to compaction shall be within ± 2 % of the target determined
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10 Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
appropriate with the thickness of the layer being compacted. The vibration mode must be set
nt
on high amplitude to achieve maximum penetration of compactive effort.
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11 The rolling pattern should first concentrate on the middle section between the rear wheel
paths of the recycler, then across the full cut width to achieve uniform density. The travel
speed of the roller shall not exceed 3 km/h.
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12 When initial compaction is complete, the surface shall be struck off to level by a grader and
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the surface again checked for level and any defects or damage caused during the operation
which shall be corrected prior to final compaction.
di
13 Where the recycler has a screed finisher which achieves the required level, initial
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compaction shall follow the recommendations of the recycler supplier.
14 Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
a
recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
ar
excessively over or under bindered, or watered.

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rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking
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applied at a rate of 5.5 to 7.0 kg/m2.
16 Traffic, including delivery vehicles shall not be permitted on the uncompacted or semi-
compacted recycled material. The exposed longitudinal joint shall be protected from damage
by construction plant and vehicles.
8.5.4 Exsitu Production Of Bitumen Stabilised Material
1 The exsitu production of BSM shall be produced by specialist recycling and stabilisation
production equipment specifically designed for the purpose of exsitu processes.
2 The bitumen shall be supplied to the mixer by specifically designed and calibrated metering
apparatus to ensure the correct addition of the binder. The addition shall be continuously
monitored with records taken to confirm the target addition rate, ± 10%, according to the mix
design.
3 The active filler (cement) shall be supplied to the mixer by specifically designed and
calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder.
The addition shall be continuously monitored with records taken to confirm the target
addition rate, ± 10%, according to the mix design.
stop when bitumen streaks or blotches are observed or where cement is seen to
agglomerate or not fully mix in during the production process.
5 BSM shall not segregate significantly during production and all measures shall be taken to
avoid this occurrence.
6 BSM shall be conveyed from the mixer to its place in the Works as rapidly as possible in
covered vehicles which will prevent segregation or drying out and ensure that the material is
of the required workability and moisture content at the point of delivery to the paving
equipment.
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in
7 Where BSM is produced on an exsitu production plant, the material shall be laid and fully
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compacted within 2 hours of production, ensuring that the moisture content is within the
required limits at the time of laying. BSM that exceeds 2 hours shall be rejected.
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8.5.5 Laying And Compaction Of Bitumen Stabilised Material
1 nt
Exsitu produced BSM materials shall be laid with paving machines and compaction plant as
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detailed in Section 6 Part 5, but may include additional specialist equipment deemed
appropriate indicated in the detailed method statement.
&
2 The BSM moisture content prior to compaction shall be within ± 2 % of the target determined
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3 Material shall be laid to a thickness that would result in layers not more than 150 mm thick
di
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4 Final compaction for BSM shall follow the general requirements Section 6 Part 5 using a
a
combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
ar
the approved method statement.

-s
5 Where the surface of the recycled layer has been graded to level, it may be dampened with
a water spray prior to compaction. Care shall be taken not to use excessive watering.
al
7 Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
the requirements of Section 6 Part 5 shall be followed.
8 After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
2
2
8.5.6 Joints In Bitumen Stabilised Material
1 Transverse joints shall be made by cutting back at least 2 metres to the position of
conforming level and compaction, and cleaned to remove any loose material. The joint shall
be fully compacted and left level and smooth.
2 Longitudinal joints shall be formed as follows:

(a) For paver laid materials, fresh joints may be formed by compacting 500mm at the
edge of the initial stabilised strip with a single roller pass and abutting the adjacent
new strip prior to cross compaction. Joints are deemed to be fresh when the pavement
materials on both sides of the joint have been stabilised and are able to be compacted
within 1 hour. The 500mm partially compacted strip together with the exposed edge
shall be lightly moistened prior to placement of the second strip.
(b) For paver laid materials and where the stabilised layer has been laid previously or is
deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and
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cleaned to remove any loose material prior to paving the new adjacent strip.
in
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3 Longitudinal construction joints in BSM shall always be formed at the lane line marking
positions where practically possible.
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8.5.7 Sampling And Testing - Bitumen Stabilised Material
1 nt
The Contractor shall produce an inspection and test plan for the complete process which
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shall include daily production control and the finished stabilised pavement for approval by the
Engineer.
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2 Bulk samples shall be taken from the stabilised material to the full depth of the layer.
ng
3 Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
protected from the heat and sun in an ambient temperature of no greater than 20°C.
di
4 Samples shall be provided from the laid BSM before compaction, as approved by the
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Engineer. One group of five samples shall be provided from five locations equally spaced
2
along a diagonal that bisects each 800m or part thereof laid each day. The number of
groups may be increased if required by the Engineer.
a
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5 For each group, 3 specimens for strength based testing shall be compacted within 2 hours of
the addition of the bitumen binder. Reference density and UCS shall be compacted and
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cured in accordance with AASHTO T-180, and tested in accordance with ASTM D1633. ITS
testing shall be compacted in accordance with ASTM D6926 and tested in accordance with
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ASTM D6931.
6 The foamed bitumen expansion ratio and half life shall be determined at the commencement
of works each day if required by the Engineer.
7 To determine the reference density of test specimens the mould shall be weighed prior to
making the specimen and the mass recorded. Immediately after completion of compaction,
the specimen and mould shall be weighed and the mass recorded. These masses together
with the nominal volume of the mould shall be used to derive the reference density of the
specimen.
8 The in-situ density of a layer of cement bound material shall be taken as the average of the
2
densities at five locations equally spaced along a diagonal that bisects each 800 m or part
thereof laid each day. The in-situ density at each location shall be the average of two
readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
9 Testing for BSM shall be required as Table 8.3 Sampling and Testing Requirements for
BSM.
Table 8.3 Sampling and Testing Requirements for BSM

SPECIFICATION
TEST METHOD SAMPLE POINT FREQUENCY
LIMIT
Pre-Stabilised Design mix 3

Sieve Analysis ASTM D422 1/1000m
Pulverised Materials gradation
Pre-Stabilised 3
Liquid Limit ASTM D4318 Maximum 25 1/1000m
Pulverised Materials
Pre-Stabilised 3
Plasticity Index ASTM D4318 Maximum 6 1/1000m
Pulverised Materials
g
ASTM Compacted Stabilised 100% reference 2
Field Density 5/800m
in
D1556/D6938 Material density
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Field Moisture Pre-compacted 2
ASTM D4944 ± 2% OMC 1/800m
Content Stabilised Material
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Surface Compacted Stabilised Report Test 2
ASTM E2583 5/800m
Modulus Material
nt Values
1
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Binder Pre-mixing/ 1/first 500
This Part:‎8.6 >10 times 2
Expansion Ratio stabilisation m /day
&
Binder Half Life Pre-mixing/ 1/first 500

This Part:‎8.6 > 12 seconds 2
(τ½) stabilisation m /day
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Unconfined
ASTM D1633 Pre-compacted 2
Compressive 1200 to 3500 kPa 1/800m
(150mmØ) Stabilised Material
Strength
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Moisture Laid Stabilised 2

ASTM D2216 ± 2% OMC 1/800m
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Content Material
Indirect Tensile ASTM D6931 Pre-compacted ITSdry >225 kPa 1/day if

2
Strength (100mmØ) Stabilised Material ITSwet >100 kPa >800m
a
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Tensile Strength Pre-compacted 1/day if

ITSwet / ITSdry > 80% 2
Retained (TSR) Stabilised Material >800m
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Note 1 – The surface modulus determined in accordance with ASTM E2583 shall be reported as
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directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
criteria.
8.5.8 Evenness And Level
1 The transverse regularity of the surface of the BSM shall be tested by means of a 4 metre
long straight edge. No irregularity in excess of 10 mm shall be permitted.
2 The longitudinal regularity of the surface of the BSM shall be tested by means of a rolling
straight edge. No irregularity in excess of 10 mm shall be permitted.
the designated grade levels to within ± 10 mm.
reshaping by adding or removing material as necessary, adding water if necessary and
recompacting the layer. The minimum length of rectification shall be 50 metres.
5 Acceptance of the stabilised pavement is subject to completion of all testing and inspection
requirements to the satisfaction of the Engineer.
8.6 DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN

(EXPANSION RATIO AND HALF LIFE)
8.6.1 Scope
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1 The foaming characteristics of bitumen are defined by the Expansion Ratio and Half Life of
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the bitumen in its expanded state. The expanded state of the bitumen is achieved when a
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small percentage of water is introduced into hot bitumen. The objective is to determine the
percentage of water required that will produce the best foam characteristics for a particular
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source of bitumen. The aim is to produce foamed bitumen with the largest expansion ratio
with the longest half-life possible.
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8.6.2 Definitions
1 The expansion ratio is a measure of the viscosity of the foam and provides an indication of
&
how well the binder will disperse in the mix. It is calculated as the ratio of the maximum
volume of foam relative to the original volume of bitumen. The half-life is a measure of the
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stability of the foam and provides an indication of the rate of collapse of the foam during
mixing. It is calculated as the time taken in seconds for the foam to collapse to half of its
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maximum volume.
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8.6.3 Apparatus
1 The following equipment shall be required:

a
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(a) For mix design only: Foamed Bitumen Laboratory Unit, capable of producing foamed
bitumen at a rate of between 50g and 200g per second. The method of production
-s
shall closely simulate that of full scale production of foamed bitumen on the recycling
machine. The apparatus shall have a thermostatically controlled kettle capable of
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holding a mass of 10kg of bitumen at a constant temperature between the range of

160ºC and 200ºC, ± 5ºC. The unit shall have an expansion chamber similar to that on
the recycling machine in which cold water is injected into hot bitumen. Water injection
shall be variable from 0 to 5% (by mass of the bitumen) with an accuracy of 0.25%.
The plant shall capable of accurately discharging a predetermined mass of foamed
bitumen directly into the mixing bowl of an electrically driven laboratory mixer with a
minimum capacity of 10kg.
(b) Cylindrical metal container, 250mm diameter and at least 20 litre capacity.
(c) Calibrated Dip Stick, calibrated for the cylindrical metal container with 500g of bitumen
as 1 unit measure. Prongs are attached to the dip stick at every 5 or 6 times the unit
volume.
(d) A stop-watch with 60 second dial.
(e) Heat resistant gloves.
(f) An electronic balance to weigh up to 10kg, accurate to 1g.
8.6.4 Method
1 Preparation
(a) The foamed bitumen laboratory unit discharge rates are checked in accordance with
the manufactures specifications. If the unit is being used for the first time then the
pump rate and water flow rates need to be calibrated as per the manufactures
specifications. Check that 500g of bitumen is being discharged at the predetermined
settings.
(b) Ensure that the cylindrical metal container and dip stick are reasonably clean.
Discharge foamed bitumen, at least twice, into cylindrical metal container prior to
testing in order to pre-heat the container. Decant excess bitumen from the container
into a suitable waste receptacle.
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2 Testing
in
(a) Heat the bitumen in the kettle of the foamed bitumen laboratory unit with the pump
ct
circulating the bitumen through the system until the required temperature is achieved
(normally starting with 160 °C). Maintain the required temperature for at least 5
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minutes prior to commencing with testing.
(b)
nt
Set the water flow-meter to achieve the required water injection rate (normally starting
with 2 % by mass of the bitumen).
co
(c) Discharge foamed bitumen into the preheated steel drum for the calculated spray time
for 500 g of bitumen. Immediately after the foamed bitumen discharge stops, start a
&
stopwatch.
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(d) Using the calibrated dipstick measure the maximum height the foamed bitumen
achieves in the drum. This maximum volume is recorded as the expansion. Continue
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to measure the time in seconds that the foam takes to dissipate to half of its maximum
volume. This is recorded as the foamed bitumen’s half-life.
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(e) Repeat the above procedures three times or until similar readings are achieved.
(f) The expansion and half-life are determined at different percentages of water.
a
Typically, values of 2 %, 3 % and 4 % by mass of bitumen are used.

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(g) Plot a graph of the expansion ratio versus half-life at the different water injection rates
-s
on the same set of axes. The optimum water addition is chosen as an average of the
two water contents required to meet the minimum criteria. (Figure 7.1 Determination of
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Optimum Foaming Water)

(h) If the required properties are not met at 160°C, further testing should be carried out
with the bitumen at higher temperatures (typically 170°C and 180°C).
8.6.5 Reporting
1 The foamed bitumen characteristics and optimum water content are reported as;
Optimum water content (%): Percentage by mass of bitumen;
Expansion (times): Ratio of maximum expansion to original volume of bitumen;
Half-life (sec): Time taken from maximum expansion to half this volume.
8.6.6 Site Quality Control

The above method may be used to determine the expansion ratio and half-life of foamed
bitumen dispensed by the production plant or recycler.
g
in
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Figure 7.1 Determination of Optimum Foaming Water
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&
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APPENDIX
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GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED
MATERIALS (MIX DESIGNS)
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8.7 GENERAL 23
8.7.1 PREPARATION OF SAMPLES FOR MIX DESIGN PROCEDURES 23
8.7.2 MIX DESIGN PROCEDURE FOR CEMENT STABILISED MATERIALS 25
8.7.3 MIX DESIGN PROCEDURE FOR BITUMEN STABILISED MATERIALS (BSMS) 27
8.7.4 DETERMINATION OF THE FLUID / DENSITY RELATIONSHIP 28
8.7.5 PREPARATION FOR STABILISING W ITH BITUMEN EMULSION (BSM-EMULSION) 29
8.7.6 PREPARATION FOR STABILISING W ITH FOAMED BITUMEN (BSM-FOAM) 29
8.7.7 MANUFACTURE OF 100MM DIAMETER SPECIMENS 32
8.7.8 DETERMINATION OF THE STRENGTH OF 100MM DIAMETER SPECIMENS 34
8.7.9 MANUFACTURE OF 150MM DIAMETER SPECIMENS 34
8.7.10 DETERMINATION OF THE STRENGTH OF 150MM DIAMETER SPECIMENS 36
8.7.11 STRENGTH TEST PROCEDURES 37
8.7.12 SELECTION OF THE AMOUNT OF BITUMEN TO BE ADDED FOR BSM 38
g
8.7.13 DETERMINATION OF THE SHEAR PROPERTIES OF BSM 40
in
8.7.14 DETERMINATION OF TRIAXIAL SHEAR PARAMETERS USING SIMPLE TRIAXIAL TEST 40
8.7.15 USING LABORATORY TEST RESULTS FOR ESTIMATING STRUCTURAL LAYER COEFFICIENTS 45
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8.7.16 PROFORMA REPORT SHEET FOR ITS TESTING 46
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8.7.17 LABORATORY EQUIPMENT REQUIREMENTS 47
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8.7 GENERAL
The detailed procedures for carrying out stabilisation mix designs in a laboratory are
described below. Procedures for both cement (or lime) and bitumen stabilisation are
included as well as guidelines for interpreting the test results for bitumen stabilised materials
(BSMs). Comprehensive lists of laboratory equipment are provided. In addition, a chart has
been included showing how laboratory test results can be utilised to indicate the relevant
structural coefficient for a BSM (for use in the AASHTO 1993 pavement design method).
8.7.1 Preparation Of Samples For Mix Design Procedures
1 Field Sampling: Bulk samples are obtained from test pits excavated as part of the field
investigations. Each layer in the upper pavement (± 300mm) must be sampled separately
and at least 150kg of material recovered from each layer that is likely to be included in any
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mix design procedure. Representative samples shall be obtained and prepared either from
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the excavation process at source or by laboratory crushing and screening.
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2 Standard soil tests: Carry out the following standard tests on the material sampled from each
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individual layer:
(a)
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Sieve analysis to determine the grading (ASTM D 422);
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(b) Atterberg limits to determine the liquid limit and plasticity index (ASTM D 4318); and
(c) Moisture / density relationship (AASHTO T-180).
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3 Sample blending: Where necessary, blend the materials sampled from the different layers to
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obtain a combined sample representing the material from the full recycling depth. The in-situ
density of the various components must be considered when blending materials, as
illustrated in
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4 Figure 7.1 Determination of Optimum Foaming Water Repeat the standard soil tests
described above to determine the grading and plasticity index of the blended sample.
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Existing upper
pavement structure
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60mm Asphalt
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3
(in situ density 2300 kg/m )
60mm Asphalt
Recycling depth 200mm
+
200mm Subbase =
3
140mm Gravel
(in situ density 2000 kg/m )
The materials are blended in proportion to layer thickness and insitu density as follows:
Per square metre Proportion by mass Per 10kg sample
Material
(kg) (%) (g)
0.06 x 2300 =
Asphalt (60mm at 2300 kg/m3) 138/418 = 0.33 0.33 x 10000 = 3300
138
0.14 x 2000 =
Gravel (140mm at 2000 kg/m3) 280/418 = 0.67 0.67 x 10000 = 6700
280
Total 418 1.00 10000
Figure 7.2 Example of Density Proportioning
5 Representative proportioning: Separate the material in the representative sample into the
following four fractions:
 Retained on the 19.0mm sieve;
 Passing the 19.0mm sieve, but retained the 12.5 mm sieve;
 Passing the 12.5 mm sieve, but retained on the 4.75mm sieve; and
 Passing the 4.75mm sieve.
Reconstitute representative samples in accordance with the grading up to the portion
passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material
that passes the 19.0mm sieve, but is retained on the 12.5 mm sieve. The example in Table
8.4 Material Combination explains this procedure:
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Table 8.4 Material Combination
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Sieve analysis Quantity of material to be included in a 10kg sample
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Sieve
Percentage passing Passing 12.5mm Passing 19mm
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size Passing 4.75mm
(from sieve analysis) Retained 4.75mm Retained 12.5mm
(mm)
19 90.5
(53.6/100 x 10000)
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((72.3-53.6)/100 x
((100-72.3)/100 x 10000)
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12.5 72.3 = 5360g
10000)
= 2770g
= 1870g
4.75 53.6
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If there is insufficient material (i.e. passing the 19mm sieve but retained on the 12.5mm
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sieve) for substituting that retained on the 19mm sieve, then lightly crush the material
retained on the 19.0mm sieve to provide more of this fraction.
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6 Sample quantities: The guidelines shown Table 8.5 Test Quantities should be used for the
quantity of material required for the respective tests:
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Table 8.5 Test Quantities

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Test Sample quantity required

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Moisture / density relationship (AASHTO T180) 5 x 7kg

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Unconfined Compressive Strength (150mm Ø specimens) 20kg per stabiliser content

Bitumen stabilisation mix design (100mm Ø specimens) Minimum 10kg per stabiliser content
Bitumen stabilisation mix design (150mm Ø specimens ) Minimum 20kg per stabiliser content
Determination of moisture content Approximately 1kg
7 Hygroscopic moisture content: Two representative air-dried samples, each approximately

1kg, are used to determine the hygroscopic (air dried) moisture content of the material.
(Note: Larger sample size should be used for more coarsely-graded materials.) Weigh the
air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a
temperature of between 105ºC and 110ºC until they achieve constant mass. The
hygroscopic moisture content (W air-dry) is the loss of mass expressed as a percentage of the
dry mass of the sample. Determine the hygroscopic moisture using equation 1:
W air-dry = (Mmoist – Mdry) / Mdry x 100 [Equation 1]
where: W air-dry = hygroscopic moisture content [% by mass]

Mmoist = mass of moist material [g]
Mdry = mass of dry material [g]
8.7.2 Mix Design Procedure For Cement Stabilised Materials
1 Determination of the Moisture / Density Relationship: This test is carried out using standard
compaction effort to determine the Optimum Moisture Content (OMC) and Maximum Dry
Density (MDD) of the cement stabilised material.
Step 1: Weigh out the required mass of stabilising agent for each of five 7kg samples
prepared as described in ‎8.7.1. The amount of stabilising agent required (expressed as a
g
percentage by mass of the dry sample) should be close to the anticipated optimum for the
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material being treated. In the absence of previous tests, the following can be used as a
guideline:
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Subbase layers: 2% for coarse material (> 50% retained on 4.75mm sieve)
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3% for fine material (< 50% retained on 4.75mm sieve)
Base layers: nt
4% for coarse material (> 50% retained on 4.75mm sieve)
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6% for fine material (< 50% retained on 4.75mm sieve)
Step 2: Add the stabilising agent to the raw material and mix immediately prior to the
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addition of water. In order to simulate conditions on the road, compaction of the stabilised
material is delayed for one hour after mixing the untreated material with stabilising agent and
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water. The mixed material is placed in an air-tight container to prevent loss of moisture and
is thoroughly mixed every fifteen minutes.
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Step 3: Determine the OMC and MDD for the stabilised material in accordance with the
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modified moisture-density relationship test procedure (AASHTO T-180).
2 Manufacture of Specimens for Strength Testing: The procedure described below is for the
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manufacture specimens that are of 150mm in diameter and 127mm in height. These
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specimens will be used to determine the Unconfined Compressive Strength (UCS) and
Indirect Tensile Strength (ITS) of the material.
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Step 1: Place the 20kg sample, prepared as described in ‎8.7.1, into a suitable mixing
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container.
Step 2: Determine the dry mass of the sample using equation 2:
Msample = (Mair-dry/ (1 + (W air-dry x 100)) [Equation 2]
where: Msample = dry mass of sample [g]

Mair-dry = air-dried mass of the sample [g]
W air-dry = moisture content of air-dried sample [% by mass]
Step 3: Determine the required amount of stabilising agent using equation 3:
Mcement = (Cadd / 100) x Msample [Equation 3]
where: Mcement = mass of lime or cement to be added [g]

Cadd = percentage of lime or cement required [% by mass]
Msample = dry mass of the sample [g]
Step 4: Determine the percentage water to be added for optimum mixing purposes using
equation 4 and then the mass of water to be added to the sample using equation 5:
W add = W OMC - W air-dry [Equation 4]
Mwater = (W add / 100) x (Msample + Mcement) [Equation 5]
where: W add = water to be added to sample [% by mass]

W OMC = optimum moisture content [% by mass]
Mwater = mass of water to be added [g]
Mcement = mass of lime or cement to be added [g]
g
Step 5: Mix the material, cement and water until uniform. Allow the mixed material to stand
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for one hour with occasional mixing, as described above, before compacting three 150mm
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diameter specimens using modified AASHTO (T-180) compaction effort. (Note: Two 150mm
diameter specimens are normally manufactured for each test.)
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Step 6: Samples are taken during the compaction process and dried to a constant mass (at
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105 to 110°C) to determine the moulding moisture content (W mould). Determine the moulding
moisture using equation 6:
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W mould = (Mmoist - Mdry) / Mdry x 100)) [Equation 6]
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where: W mould = moulding moisture content [% by mass]

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Steps 7 to 9: Repeat the above steps for at least three different stabiliser contents.
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Step 10: Remove the specimens from the moulds either by dismantling the split moulds or, if
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ordinary moulds are used, extruding the specimens carefully with an extrusion jack, avoiding
distortion to the compacted specimens.
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Step 11: Record the mass and volume of each specimen and determine the dry density
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using equation 7:
DD = (Mbriq / Vol) x (100 / W mould +100) x 1000 [Equation 7]
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where: DD = dry density [kg/m³]

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Mbriq = mass of specimen [g]

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Vol = volume of specimen [cm ]
W mould = moulding moisture content [%]
Note: With certain materials lacking cohesion, it may be necessary to leave the specimens in the
moulds for 24 hours to develop strength before extracting. When this is necessary, the
specimens in the moulds should be kept in a curing room or covered with damp cloth (hessian).
3 Curing the Specimens: Cure the specimens for seven days at 95% to 100% relative humidity
and at a temperature of 20ºC to 25ºC in a suitable curing room.
An alternative curing method is to place the specimen in sealed plastic bags and cure in an
oven at:
70ºC to 75ºC for 24 hours for cement; or
60ºC to 62 ºC for 45 hours for lime.

After the curing period, remove the specimens from the curing room (or plastic bags) and
allow to cool to ambient temperature, if necessary. Specimens for unconfined compressive
strength (UCS) tests should be submerged in water at 22°C to 25°C for four hours prior to
testing.
4 Strength Tests: The Unconfined Compressive Strength (UCS) test and the Indirect Tensile
Strength (ITS) test procedures are described under ‎8.7.11.
5 Determination of the Optimum Stabiliser Content: The ITS and UCS strengths achieved are
plotted against the percentage stabilising agent added using the average UCS or ITS of the
three specimens for each stabiliser content, ignoring any obvious incorrect result that may
have been caused by damage to the specimen before testing. The required application rate
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of stabilising agent is that percentage at which the minimum required criteria are met.
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8.7.3 Mix Design Procedure For Bitumen Stabilised Materials (Bsms)
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1 Active Filler Requirements: Bitumen stabilisation is normally carried out in combination with a
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small amount (1% by mass) of active filler (cement or hydrated lime) to enhance the
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dispersion of the bitumen and/or the breaking time (where bitumen emulsion is used as the
stabilisation agent). The PI of the material is used as an initial guideline for the use of
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hydrated lime or cement in the mix:
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Table 8.6 Guide to Addition of Active Filler

Plasticity Index: < 10 Plasticity Index: > 10
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Pre-treat with hydrated lime (ICL value)

Carry out Preliminary Level 1 tests
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(The initial consumption of lime (ICL value)

(explained below) to determine the need to
must first be determined using the
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add cement or hydrated lime.

appropriate pH test.)
Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2
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hours prior to the addition of the bitumen emulsion or foamed bitumen. (The treated material
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must be placed in an air-tight container to retain moisture and the moisture content checked
and, if necessary, adjusted prior to adding the bitumen stabilising agent.) Such materials are
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not subjected to “Preliminary Level 1” tests.

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2 Preliminary Level 1 Tests: Where the PI < 10, the need for an active filler and the type of
active filler (cement or hydrated lime) that is appropriate for the material must first be
determined by carrying out “Level 1” tests on three different mixes. The same amount of
bitumen (residual bitumen for bitumen emulsion treatment) is added to all three mixes,
determined from the fractions passing the 4.75mm and 0.075mm sieves, as shown in Table
8.7 Suggested bitumen addition relative to key aggregate fractions.
Table 8.7 Suggested bitumen addition relative to key aggregate fractions

Percentage passing sieve size (%) Bitumen addition
(% of dry aggregate)
4.75mm 0.075mm
< 5.0 2.0
5.0 – 7.5 2.25
< 50
7.5 – 10.0 2.5
> 10.0 2.75
< 5.0 2.25
5.0 – 7.5 2.5
> 50
g
7.5 – 10.0 3.0
in
> 10.0 3.5
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The first mix contains no active filler, 1% cement is added to the second mix and 1%
hydrated lime is added to the third mix. 100mm diameter specimens are manufactured,
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cured and tested to determine the relevant ITSDRY, ITSWET and TSR values as described
in ‎8.7.12.
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Where the TSR value for the mix with no active filler added is in excess of 60%, the mix
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design should be undertaken with no active filler. (This situation is usually confined to
materials consisting of good quality crushed stone, often including a high proportion of
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reclaimed asphalt pavement (RAP) material.)

Where the TSR value of the mix with no active filler added is less than 60%, the mix with the
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type of active filler that produces a significantly higher TSR value (> 5%) indicates whether
cement or hydrated lime should be used. If the TSR values for both active fillers are of the
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same order (difference < 5%) then either type of active filler is suitable.
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Note. Should cement and/or hydrated lime be not readily available and tests indicate the
need for an active, the use of 15% (by volume) quarry fine aggregate (5mm to 0mm) or
similar material with > 10% passing the 0.075mm sieve may be used as a substitute in the
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mix designs.
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8.7.4 Determination Of The Fluid / Density Relationship

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The Optimum Fluid Content (OFC) and the Maximum Dry Density (MDD) of the stabilised
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material is determined using standard compaction effort.

Note: For foamed bitumen stabilisation, the OFC and MDD can be assumed to be the same
as the OMC and MDD, as determined for representative samples of the untreated material.
The OFC for bitumen emulsion treated material is the percentage by mass of bitumen
emulsion plus additional moisture required to achieve the maximum dry density in the treated
material. As described below, the OFC is determined by adding a constant percentage of
bitumen emulsion whilst varying the amount of water added.
Step 1: Measure out the bitumen emulsion as a percentage by mass of the air-dried material
for each of five prepared samples following the procedure described in ‎8.7.1. The
percentage of bitumen emulsion added is normally between 2 and 3% residual bitumen (e.g.
for 3% residual bitumen, add 5% of a 60% bitumen emulsion).
Step 2: The bitumen emulsion and water is added to the material and mixed until uniform
immediately prior to compaction.
Step 3: Determine the OFC and MDD for the stabilised material in accordance with the
modified moisture-density relationship test procedure (AASHTO T-180).
8.7.5 Preparation For Stabilising With Bitumen Emulsion (Bsm-Emulsion)

Step 1: Place the required quantity of sample into a suitable mixing container (10kg for the
manufacture of 100mm diameter specimens, or 20kg for the manufacture of 150mm
diameter specimens).
Step 2: Determine the dry mass of the sample using equation 1.
Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
Step 4: Determine the required percentage (by mass) of bitumen emulsion using equation 8:
Memul = (RBreqd / PBE) x Msample [Equation 8]
where: Memu = mass of bitumen emulsion to be added [g]

RBreqd = percentage of residual bitumen required [% by mass]
PBE = percentage of bitumen in emulsion [% by mass]
g
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Step 5: Determine the amount of water to be added for optimum compaction purposes using
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equation 9:
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Mwater = {((W OFC – W air-dry) / 100) x Msample} – Memul [Equation 9]
where: Mwater = mass of water to be added [g]

W OFC = optimum fluid content nt [% by mass]
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Memul = mass of bitumen emulsion to be added [g]
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Step 6: Mix the material, active filler, bitumen emulsion and water together until uniform.
Immediately manufacture specimens following the relevant procedure for either 100mm or
150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.
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Repeat above steps for at least four mixes with different bitumen emulsion contents.
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Recommended bitumen addition interval for different specimen sizes

Difference in amount of bitumen added (%) to
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Specimen diameter (mm)

each mix
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100 (Level 1) 0.25

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150 (Level 2) 0.1

For 100mm diameter specimens, use Error! Reference source not found. as a guideline
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or the amount of bitumen addition that the material will require for effective stabilisation.
For 150mm diameter specimens, use the results of Level 1 tests from ‎8.7.8 as the maximum
addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
value).
8.7.6 Preparation For Stabilising With Foamed Bitumen (Bsm-Foam)
1 Determination of the foaming properties of the bitumen: The foaming properties of each
bitumen type is characterised by:
Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio
of the maximum volume of the foam relative to the original volume of bitumen; and
Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in
seconds for the foam to collapse to half of its maximum volume.
The objective is to determine the temperature and percentage of water addition that is
required to produce the best foam properties (maximum expansion ratio and half-life) for a
particular source of bitumen. This is achieved at three different bitumen temperatures (not
exceeding 195°C) with the following procedure:
Step 1: Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump
circulating the bitumen through the system until the required temperature is achieved
(normally starting with160°C). Maintain the required temperature for at least 5 minutes prior
to commencing with testing.
Step 2: Calibrate the discharge rate of the bitumen and set the timer on the Wirtgen WLB10
S to discharge 500g of bitumen (Qbitumen).
Step 3: Set the water flow-meter to achieve the required water injection rate (normally
starting with 2% by mass of the bitumen).
Step 4: Discharge foamed bitumen into a preheated (± 75°C) steel drum for a calculated
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spray time for 500g of bitumen. Immediately after the foam discharge stops, start a
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stopwatch.
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Step 5: Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel
drum of 275mm in diameter and 500g of bitumen) measure the maximum height the foamed
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bitumen achieves in the drum. This is recorded as the maximum volume.
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Step 6: Use the stopwatch to measure the time in seconds that the foam takes to dissipate
to half of its maximum volume. This is recorded as the foamed bitumen’s half-life.
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Step 7: Repeat the above procedure three times or until similar readings are achieved.
Step 8: Repeat steps 3 to 7 for a range of at least three water injection rates. Typically,
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values of 2%, 3% and 4% by mass of bitumen are used.

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Step 9: Plot a graph of the expansion ratio versus half-life at the different water injection
rates on the same set of axes (see the example in graph below). The optimum water
addition is chosen as an average of the two water contents required to meet these minimum
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criteria.
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Repeat Step 1 to 9 for two other bitumen temperatures (normally 170°C and 180°C).
The temperature and optimum water addition that produces the best foam is then used in the
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mix design procedure described below.

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Note: The absolute minimum foaming properties that are acceptable for effective
stabilisation (material temperature of 25°C) are:
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 Expansion ratio: 10 times

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 Half-life: 12 seconds
2 If the minimum requirements cannot be met, the bitumen should be rejected as unsuitable
for use.
3 Prepare the material for foamed bitumen treatment as follows:

Step 1: Place 20 to 25kg of sample prepared as described in ‎8.7.1 into the Wirtgen WLM30
pugmill mixer.
Step 2: Determine the dry mass of the sample using equation 2.
Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
Step 4: Determine the percentage water to be added for optimum mixing moisture content
as calculated using equation 10. The amount of water to be added to the sample is
determined using equation 11.
W add = 0.75W OMC - W air-dry [Equation 10]
Mwater = (W add / 100) x (Msample + Mcement) [Equation 11]
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where: W add = water to be added to sample [% by mass]
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Mwater = mass of water to be added [g]
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Step 5: Mix the material, active filler and water in the mixer until uniform.
Note: Inspect the sample after mixing to ensure that the mixed material is not packed
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against the sides of the mixer. If this situation occurs, mix a new sample at a lower moisture
content. Check to see that the material mixes easily and remains in a “fluffed” state. If any
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dust is observed at the end of the mixing process, add small amounts of water and remix
until a "fluffed" state is achieved with no dust.
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Step 6: Determine the amount of foamed bitumen to be added using equation 12:
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Mbitumen = (Badd /100) x (Msample + Mcement) [Equation 12]
where: Mbitumen = mass of foamed bitumen to be added [g]

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Badd = foamed bitumen content [% by mass]

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Step 7: Determine the timer setting on the Wirtgen WLB10 S using equation 13:
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T = Mbitumen / Qbitumen [Equation 13]
where: T = time to be set on WLB10 S timer [s]

Mbitumen = mass of foamed bitumen to be added [g]
Qbitumen = bitumen flow rate for the WLB10 S [g/s]
Step 8: Position the mixer adjacent to the foaming unit so that the foamed bitumen can be
discharged directly into the mixing chamber.
Step 9: Start the mixer and allow it to mix for at least 10 seconds before discharging the
required mass of foamed bitumen into the mixing chamber. After the foamed bitumen has
discharged into the mixer, continue mixing for a further 30 seconds or until uniformly mixed.
Step 10: Determine the amount of water required to bring the sample to the OMC using
equation 14.
= (W OMC – W sample) / 100 x (Msample +

Mplus [Equation 14]
Mcement)
where: Mplus = mass of water to be added [g]
W sample = moisture content of prepared sample [% by mass]
Mcement = mass of lime or cement added [g]
Note: This moisture adjustment is to be carried out when 150mm diameter specimens are
to be manufactured. Where 100mm diameter specimens are to be manufactured, the
moisture content of the material is to be adjusted to 90% of OMC.
Step 11: Add the additional water and mix until uniform.
Step 12: Transfer the foamed bitumen treated material into a container and immediately
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seal the container to retain moisture. To minimise moisture loss from the prepared sample,
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manufacture the specimens as soon as possible following the relevant procedure for either
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100mm or 150mm diameter specimens, as described in ‎8.7.7 and ‎8.7.9 respectively.
Repeat the above steps for at least four mixes with different foamed bitumen contents.
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Recommended bitumen addition interval for different specimen sizes
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Difference in amount of bitumen added (%)
Specimen diameter (mm)
to each mix
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100 (Level 1) 0.25

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150 (Level 2) 0.1

For 100mm diameter specimens, use Error! Reference source not found. as a guideline
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or the amount of bitumen addition that the material will require for effective stabilisation.
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For 150mm diameter specimens, use the results of Level 1 tests in ‎8.7.8 as the maximum
addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
value).
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8.7.7 Manufacture Of 100mm Diameter Specimens

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1 For Level 1 mix designs ITS tests are carried out on 100mm diameter specimens. Six
specimens are manufactured for each sample at the different bitumen contents. The two
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primary objectives of undertaking the Level 1 mix design are to determine:

 the optimum bitumen content for the BSM, and
 the need for an active filler.
2 Specimens may be made using either Marshall or vibratory compaction methods.
3 Marshall Compaction shall be carried out as follows:

Step 1: Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate
and face of the compaction hammer.
Note: the compaction equipment must not be heated but kept at ambient temperature.
Step 2: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm
(usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
and 10 times on the surface, leaving the surface slightly rounded.
Step 3: Compact the mixture by applying 75 blows with the compaction hammer. Care must
be taken to ensure the continuous free fall of the hammer. Remove the mould and collar
from the pedestal, invert the specimen (turn over). Replace it and press down firmly to
ensure that it is secure on the base plate. Compact the other face of the specimen with a
further 75 blows.
Step 4: Take approximately 1kg representative samples after compaction of the second and
fifth specimen and dry a constant mass (at 105 to 110°C). Determine the moulding moisture
using equation 15:
W mould = (Mmoist – Mdry) / Mdry x 100 [Equation 15]
where: W mould = moulding moisture content [% by mass]

g
Step 5: After compaction, remove the mould from the base-plate and extrude the specimen
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by means of an extrusion jack. Measure the height of the specimen and adjust the amount
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material if the height is not within the required limits.
Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
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the mould for 24 hours, allowing sufficient strength to develop before extracting.
4 Vibratory Compaction shall be carried out as follows:nt

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Step 1: Fix the mounting head and appropriate tamping foot to the vibratory hammer and fit
hammer onto guide rods. Place 5kg surcharge weight onto mounting head (total mass of
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assembly [Hammer + foot + surcharge] = 25kg) and fasten tightly. Using the pulley system
raise the vibratory hammer to an adequate height that will allow operator to work safely
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beneath the vibratory hammer and lock in position.

Step 2: Clean the mould, collar and base plate. Fix the mould to the base of the compaction
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frame.
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Note: the compaction equipment must not be heated but kept at ambient temperature.
Step 3: Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm
(usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
a
and 10 times on the surface, leaving the surface slightly rounded.

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Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is
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perpendicular to the base of the mould. Apply 15 seconds of vibratory compaction to the
sample in the mould.
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Step 5: Raise hammer to the safe position, remove mould, invert mould and secure to base.
Step 6: Lower vibratory hammer to surface of material in mould and ensure vibratory
hammer rests freely on sample and is perpendicular to the base of the mould. Apply further
15 seconds of vibratory compaction to sample in the mould.
Step 7: Take approximately1kg representative samples after compaction of the second and
fifth specimen and dry to constant mass (at 105 to 110 oC). Determine the moulding
moisture using equation 15.
Step 8: After compaction, remove the mould from the base-plate and extrude the specimen
carefully by means of an extrusion jack.
5 Curing procedure: Compacted specimens shall be cured by placing the specimens on a steel
mesh and curing in a forced-draft oven until a constant mass is obtained (normally 72 hours
at 40°C). Remove from oven after curing and allow to cool to ambient temperature.
6 When specimens have cooled to ambient temperature determine the bulk density for each
specimen:
Step 1. Determine the mass (Mbriq).
Step 2. Measure the height at four evenly-spaced places around the circumference and
calculate the average height (h).
Step 3. Measure the diameter (d).
Step 4. Calculate the bulk density using equation 16:
2
BD = (4 x Mbriq x h) x 1000 [Equation 16]
g
where: BD = moulding moisture content [kg/m³]
in
Mbriq = mass of specimen [g]
ct
h = average height of specimen [cm]
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d = diameter of specimen [cm]
nt
Note: Exclude from further testing any specimen whose bulk density differs from the mean
bulk density of the batch by more than 50 kg/m³.
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7 The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water”
method for those specimens designated for soaked testing.
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8.7.8 Determination Of The Strength Of 100mm Diameter Specimens

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1 The 100mm diameter specimens are tested for indirect tensile strength under dry and
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soaked conditions to determine the ITSDRY and the ITSWET values. To prevent moisture loss,
specimens should be tested as soon as they are prepared. The results are used to indicate
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the optimum bitumen content and the need for active filler. In addition, these test results are
used as a guide for the classification of the BSM.
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8.7.9 Manufacture Of 150mm Diameter Specimens

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1 Level 2 mix designs ITS tests are carried out on specimens that are 150mm diameter and
95mm in height. These specimens are cured to simulate the equilibrium moisture content
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achieved in the field. This method of curing provides more realistic values for classification of
the bitumen stabilised materials.
2 The procedures described allow for the manufacture of four 150mm diameter specimens to a
compacted height of 95mm. If additional specimens are required, the sample quantity shall
be increased.
3 Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
methods.
4 MODIFIED AASHTO (T-180) compaction shall be carried out as follows:

Step 1: Prepare and treat at least 24kg of sample for each selected bitumen content.
Step 2: Where required, add sufficient moisture to bring sample to optimum compaction
moisture content and mix until uniform. Immediately after mixing, place material in an air-
tight container.
Step 3: Take approximately 1kg representative samples after compaction of the first and
third specimen and dry to a constant mass (at 105 to 110°C). Determine the moulding
moisture using equation 15.
Step 4: Compact at least 4 specimens using a 150mm diameter split-mould, applying
modified AASHTO (T-180) compaction effort (4 layers approximately 25mm thick, 56 blows
per layer using a 4.536kg hammer with a 457mm drop).
Step 5: Carefully trim excess material from specimens, as specified in the AASHTO T180
test method.
Step 6: Carefully remove the specimen from the spilt-mould and place on a steel mesh.
5 Vibratory compaction shall be carried out as follows:
g
Step 1: Fix the mounting head and appropriate tamping foot (150mm diameter) to the
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vibratory hammer and fit hammer onto guide rods. Place 10kg surcharge weight onto
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mounting head (total mass of assembly [hammer + foot + surcharge] = 30kg) and fasten
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tightly. Using the pulley system raise the vibratory to an adequate height that will allow
operator to work safely beneath the vibratory hammer and lock in position.
nt
Step 2: Clean the 150mm diameter spilt mould, collar and base plate. Fix the mould to the
base of the compaction frame.
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Step 3: Weigh sufficient material to achieve a compacted height of 47.5mm ± 1.5mm. An
approximation of the quantity required can be calculated using equation 17. Spade the
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mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving
the surface slightly rounded.
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2
Mmix = ( x d x h / 4) x (MDD) /1000 [Equation 17]
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where: Mmix = Mass of mixed material [g]

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h = required height of layer (4.75cm for ITS) [cm]
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MDD = maximum dry density [kg/m³]

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perpendicular to the base of the mould.
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Apply 25 seconds of vibration for bitumen emulsion stabilised materials

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35 seconds of vibration for foamed bitumen stabilised materials.

Step 5: Raise hammer to safe position.
Step 6: For the second layer, if necessary, adjust for the amount of material to be added
such that the final compacted thickness is 95mm. Using a chisel, scarify the entire surface
area of the top of the compacted layer to a maximum depth of 10mm. Add the required
amount of material and ensure the material is as level as possible.
perpendicular to the base of the mould.
Apply 25 seconds of vibration for bitumen emulsion stabilised materials
35 seconds of vibration for foamed bitumen stabilised materials.
Step 8: Raise hammer to safe position. Remove mould from base plate and open the split
mould to remove the specimen.
Step 9: Take approximately 1kg representative samples after compaction of the first and
third specimens and dry to a constant mass. Determine the moulding moisture using
equation 15.
6 Curing procedure: Place the specimens in an oven at 40°C for 24 hours (or until the moisture
content has reduced to at least 50% of OMC). Thereafter place each specimen in a sealed
plastic bag (at least twice the volume of the specimen) and place in an oven at 40°C for a
further 48 hours.
7 Remove specimens from the oven after 48 hours and remove the respective plastic bags,
ensuring that any moisture in the bags does not come into contact with the specimen. Allow
to cool to ambient temperature.
g
in
8 When specimens have cooled to ambient temperature determine the bulk density for each
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specimen:
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Step 1: Determine the mass (Mbriq).
Step 2: Measure the height at four evenly-spaced places around the circumference and
calculate the average height (h).
nt
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Step 3: Measure the diameter (d).
Step 4: Calculate the bulk density using equation 16:
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Note: Exclude from further testing any specimen whose bulk density differs from the mean
bulk density of the batch by more than 50 kg/m³.
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9 The bulk density may alternatively be determined by using the “weigh-in air / weigh-in water”
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method for those specimens designated for soaked testing.

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8.7.10 Determination Of The Strength Of 150mm Diameter Specimens
1 The 150mm diameter specimens are tested for indirect tensile strength under equilibrium
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moisture content and soaked conditions to determine the ITSEQUIL and the ITSSOAK values. To
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prevent moisture loss, specimens should be tested as soon as they are prepared. The
results are used to refine the optimum bitumen content and amount of active filler that was
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initially determined from the 100mm diameter specimens. In addition, these test results are
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used to classify the BSM with additional confidence.
2 Additional ITS tests should be carried out using 150mm diameter specimens to determine
the sensitivity of the mix to minor variations in both the amount of added bitumen and active
filler.
If, for example, Level 2 test results indicated an optimum bitumen addition (OBA) of 2.2%
with an active filler addition of 1%, then the following further tests should be undertaken:
Step 1: To check the sensitivity of the bitumen addition, follow the Level 2 procedure in ‎8.7.9
to manufacture, cure and test the following mixes:
Added bitumen (%) Active filler (%)

2.2 (Level 2 OBA) 1
2.1 1
2.0 1
1.9 1
ITS test results will allow the optimal bitumen addition (OBA) to be refined.
Step 2: To check the sensitivity of the amount of active filler added, follow the Level 2
procedure in ‎8.7.9 to manufacture, cure and test the following mixes:
Added bitumen (%) Active filler (%)
OBA 0.9
OBA 0.7
OBA 0.5
g
ITS test results will indicate the minimum amount of active filler required in the mix.
in
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8.7.11 Strength Test Procedures
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1 The Unconfined Compressive Strength (UCS) of a cement stabilised material is determined
by measuring the ultimate load to failure of a 127mm high and 150mm diameter specimen
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that is subjected to a constant loading rate of 140kPa/s (153kN/min), as follows:
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Step 1: Place the specimen on its flat side between the plates of the compression testing
machine. Position the specimen such that it is centred on the loading plates.
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Step 2: Apply the load to the specimen, without shock, at a rate of advance of 140kPa/s until
the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.
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Step 3: Immediately after testing a specimen, break the specimen up and take a sample of
approximately 1000g to determine the moisture content (W break). This moisture content is
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used to determine the dry density of the material using equation 21.
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Step 4: Calculate the UCS for each specimen to the nearest 1 kPa according to equation 18.
= (4 x P) / (  x d ) x 10000
2
UCS [Equation 18]
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where: UCS = unconfined compressive strength [kPa]

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P = maximum load to failure [kN]

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2 Indirect Tensile Strength (ITS) of a stabilised material is determined by measuring the

ultimate load to failure of a specimen (both 100mm and 150mm diameter specimens) that is
subjected to a constant deformation rate of 50.8 mm/minute on its diametrical axis, as
follows:
Step 1: Place the specimen onto the respective ITS jig for the 100mm and 150mm diameter
specimens. Position the sample such that the loading strips are parallel and centred on the
vertical diametrical plane.
Step 2: Place the load transfer plate on the top bearing strip and position the jig assembly
centrally under the loading ram of the compression testing device.
Step 3: Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per
minute until the maximum load is reached. Record the maximum load P in kN, accurate to
0.1kN.
Step 4: Immediately after testing a specimen, break it up and take a sample of

approximately 1000g to determine the moisture content (W break). This moisture content is
used in equation 21 to determine the dry density of the material in the specimen.
Step 5: Immediately after testing a specimen, measure the temperature of the broken face
using a digital thermometer. Record the temperature, accurate to 0.1°C.
Step 6: Calculate the ITS for each specimen to the nearest 1 kPa using equation 19:
ITS = (2 x P) / ( x h x d) x 10000 [Equation 19]
where: ITS = indirect tensile strength [kPa]

P = maximum applied load [kN]
h = average height of the specimen [cm]
g
Step 7: To determine the soaked ITS, place the specimens under water at 25°C ± 1°C for 24
in
hours. Remove specimen from water, surface dry and repeat steps 1 to 5.
Record the results and determine the following as required:
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100mm Ø specimens: ITSDRY = average of 3 specimens cured to constant mass
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ITSWET = average of 3 ITSDRY specimens soaked for 24 hours.
150mm Ø specimens: ITSEQUIL = average of 2 specimens cured at equilibrium moisture
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ITSSOAK = average of 2 ITSEQUIL specimens soaked for 24 hours
Step 8: Determine the Tensile Strength Retained (TSR). The TSR is the relationship
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between the average soaked and unsoaked ITS values for a specific batch of specimens,
expressed as a percentage using equation 20:
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TSR = Average soaked ITS / Average unsoaked ITS x 100 [Equation 20]
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Step 9: Using the moisture content determined in each test described above, calculate the
dry density using equation 21:
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DD = (Mbriq / Vol) x (100 / (W break + 100) x 1000 [Equation 21]

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where: DD = dry density [kg/m³]

Mbriq = mass of cured specimen [g]
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3
Vol = volume of specimen [cm ]
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W break = moisture content of the specimen [%]

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Report the results using the template sheet shown in ‎8.7.16 as a guide.
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8.7.12 Selection Of The Amount Of Bitumen To Be Added For Bsm
1 Plot the results of the respective soaked and unsoaked ITS test results against the relevant
bitumen content that was added. The added bitumen content that best meets the desired
BSM classification is selected as the optimum amount of bitumen to be added, as shown in
the example below (Figure 7.3 Determination of BSM class and added bitumenFigure 7.3
Determination of BSM class and added)
Interpretation of ITS Tests
Test Specimen Ø BSM1 BSM2 BSM3 Purpose
Indicates the optimum bitumen

ITSDRY 100 mm > 225 175 to 225 125 to 175
content
ITSWET 100 mm > 100 75 to 100 50 to 75 Indicates need for active filler.
Indicates problem material where

TSR 100 mm N/A N/A N/A
TSR < 50 and ITSDRY > 400 kPa
Used for classifying the BSM and
ITSEQUIL 150 mm > 175 135 to 175 95 to 135 for optimising the bitumen and
active filler content.
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ITSSOAK 150 mm > 150 100 to 150 60 to 100 Check value on ITSWET
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Figure 7.3 Determination of BSM class and added bitumen

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2 The TSR value is useful for identifying problem materials. If the TSR is less than 50%, it is
recommended that active filler is used. If such treatment does not increase the ITSWET value
with a maximum application of 1% lime or cement, then the nature of the material being
stabilised should be investigated:
3 Where the material is granular, a TSR value below 50% combined with an ITSDRY value in
excess of 400 kPa suggests contamination (normally attributed to clay or deleterious
materials). In this situation, it is suggested that material is pre-treated with hydrated lime and
the Level 1 tests repeated.
4 Where the material is 100% RAP, a TSR value below 50% combined with an ITSDRY value in
excess of 500 kPa indicates that the treated material is partly stabilised and partly
continuously bound (cold mix). In this situation, the material probably requires blending with
crusher dust to ensure that the stabilisation process dominates the mix.
5 Level 2 testing using 150mm diameter specimens should be undertaken to verify the
relevant ITS values for BSM classification.
8.7.13 Determination Of The Shear Properties Of Bsm
1 Triaxial testing is carried out to determine the cohesion and angle of internal friction of BSM
specimens. Testing is normally carried out at the bitumen content selected from the results
of ITS tests carried out on 150mm diameter specimens (see above). Additional tests at
different bitumen contents can always be carried out to investigate the sensitivity of the
shear properties.
2 Specimens for triaxial testing shall be produced as follows:

Step 1: Prepare and treat 50kg of sample (adequate for manufacture of 4 specimens) with
either bitumen emulsion or foamed bitumen at the optimum bitumen content. Include any
g
active filler requirements.
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Step 2: Where required, add moisture to bring sample to optimum compaction moisture
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content and mix until uniform. Place the mixed material in an air-tight container.
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Step 3: Take approximately1 kg representative samples of each specimen to determine the
moulding moisture using equation 15.
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Step 4: Compact at least four (4) specimens using a 150mm diameter split mould with an
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effective internal height of 300mm, using equation 17 to calculate the approximate quantity
for each layer.
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3 Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
methods.
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4 Compaction using modified AASHTO (T180) shall be in 12 layers, each approximately 25mm
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thick, compacted with 56 blows using a 4.536kg hammer with a 457mm drop. Carefully trim
any excess material from the specimen.
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5 Compaction using vibratory compaction shall be in 5 layers, each approximately 60mm thick,
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using a hammer assembly of 30kg total mass. Each layer is compacted for:
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 25 seconds for BSM-emulsion, or


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35 seconds for BSM-foam

The height of each compacted layer is measured and, if necessary, an adjustment made for
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the quantity of material used for the next layer to achieve the required height for the
respective layers.
6 The specimens shall be cured using the same procedure for 150mm diameter specimens.
8.7.14 Determination Of Triaxial Shear Parameters Using Simple Triaxial Test
1 This method describes the determination of triaxial shear parameters (cohesion and internal
angle of friction) of Bitumen Stabilised Materials by measuring the resistance to failure
(monotonic) of a cylindrical 150 mm diameter and 300 ± 2 mm height specimen prepared
according to Vibratory Hammer Compaction Procedure.
2 Apparatus:
(a) Triaxial Cell comprising a galvanised steel casing 5 mm thick comprising a ring handle
and simple mechanical clamps top and bottom, a base with bottom platen for sitting
specimen, top disk and a latex tube at least 320 mm in height.
(b) Testing System comprising a Material Testing System (MTS) or its equivalent system
must at least comprise of an actuator, reaction frame, a control panel and data
acquisition system. The system must be capable of providing ramp loads with
minimum loading capacity of 100 kN and a minimum stroke of 40 mm. The actuator
should be operated by a servo-controlled hydraulic pressure system with a closed loop
feedback system that is capable of both displacement and load controlled testing if
required.
(c) Measuring devices should include but not limited to a load cell (100 kN Capacity) for
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measuring load, an actuator displacement transducer (> 40 mm stroke) for measuring
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displacement (deformation) and pressure regulator, gauges, and valves for lateral
pressure.
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(d) Additionally air compressor, loading ram and silicon oil or grease.
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3 The specimen must be prepared and cured according to Vibratory Hammer Compaction
Procedure as stated previously. nt
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4 The triaxial testing of the specimens must be planned to take place within 48 – 72 hours after
completion of the curing procedure. This delay must be kept as constant as possible. The
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following steps describe the procedure taken to assemble specimen in the simple triaxial cell
and the cell in the loading frame:
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(a) Place the specimens, casing with tube, top disk and base plate in a climate chamber
and condition them overnight at 25ºC.
di
(b) Lightly grease the sides of the top disk and base plate to reduce friction as much as
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possible.
(c) Place the specimen in the middle of the base plate.
a
(d) Carefully introduce the casing, comprising the tube, around the specimen. Take care
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not to damage the edges of the specimen during this procedure.

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(e) Clamp the casing in position on to the base plate using simple mechanical clamps on
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the casing.
(f) Put the top disk on top of the specimen.
(g) Place the cell in the hydraulic loading frame; adjust actuator position until visual
contact is made with the loading ram.
(h) Connect the air supply to the cell; open the regulator and valve on the cell pressure
port until the cell pressure is stable at the desired level.
(i) Set monotonic test parameters on the MTS controller including displacement rate of
strain (2.1%), full-scale for the loading (10.0V = 98.1 kN) and half-scale for the
displacement (10.0V = 40mm), and run the test
5 Monotonic Triaxial Test: Select four specimens of comparable density, moisture content and
conditioned at 25°C. Assemble the specimen in the triaxial cell according to 4 ensuring the
tube is air tight.
(a) Operate the testing system in displacement control mode. Ensure that there is
sufficient space between the actuator and the reaction frame to accommodate the
triaxial cell. Place the triaxial cell in the hydraulic loading frame.
(b) Adjust the actuator position until visual contact is made with the loading ram. Monitor
the load cell reading to prevent loading of the specimen during this process. Connect
the air supply to the cell pressure port. Open the valve on the cell pressure port and
open the regulator until the cell pressure is stable at the desired level. The cell
pressures for a series of monotonic tests are 0 kPa, 50kPa, 100 kPa and 200 kPa.
(c) Test the first specimen without confinement pressure (0 kPa). Begin the test by
compressing the specimen at a constant rate of displacement of 2.1%. Record the
load versus displacement during the test with a minimum sampling rate of 10 Hz, as
well as the cell pressure, temperature and specimen identifier.
g
(d) Stop the test and the recording when the total displacement exceeds 18 mm (6%
in
strain) or when the specimen bulges excessively before the end displacement is
reached.
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(e) Repeat this procedure for other three specimens until all specimens have been tested
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at the four levels of confinement pressures.
6 nt
Remove the specimens after completion of test after completion of a test. Hold the actuator
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to its current position, close the valve on the cell pressure port and release the cell pressure
by disconnecting the pressure supply tube to the cell (if possible speed up the pressure
release by applying suction). Return the actuator to a position whereby the cell can easily be
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removed from the loading frame. Remove the top disk. Clean the top disk and wipe off any
grease. Unclamp the casing and lift the casing with tube from the cell base. Clean the tube
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from possible remains of the deformed specimen (it is not necessary to remove the tube
from the casing). Remove the tested specimen from the base plate. Place it in the plastic
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bag and seal. Clean the base plate and wipe off any grease.
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7 When all the specimens have been tested, remove the tested specimens one by one from
the plastic bags. Break the tested specimens up and sample between 500 and 1000 gr. of
a
material from the middle of the specimen. Use this sample to determine the moisture content
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of each specimen.
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8 Calculations:
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(a) Determine the applied failure load Pa,f for each specimen tested. The applied failure
load is defined as the maximum applied load during the test. Calculate the applied
failure stress σa,f :
σa,f
where: σa,f = applied failure stress [kPa]

Pa,f = applied failure load [N]
2 2
A = end area of a cylindrical specimen at beginning of [m ] or mm ??
test
(b) Calculate the major principle stress at failure σ1,f for each tested specimen:
σ1,f = σa,f + σdw
where: σ1,f = major principle stress at failure [kPa]

σa,f = applied failure stress [kPa]
σdw = pressure resulting from dead weight of top disk and [kPa]
loading ram
(c) The relationship between σ1,f and confinement stress (σ3)is determined by:
σ1,f = A.σ3+B
A
where:
g
B
in
Values of A and B can be determined by performing a linear regression analysis on the
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four combinations of σ1,f and σ3 per mix.
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(d) Values of φ [°] and C [kPa] can be calculated as follows:
where:
φ nt
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C
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9 Report the following in the table format as illustrated in

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10 Table 8. 8 Format Report for Simple Triaxial Test below:

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(a) Specimen number or identifier;

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(b) Confinement pressure (σ3);

(c) Applied stress at failure (σa,f);
a
(d) Major principal stress at failure (σ1,f);

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(e) Cohesion, C [kPa];

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(f) Angle of internal friction, φ [°]; and

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2
(g) Coefficient of variance, R
11 Plot the Mohr Circles and the Mohr-Coulomb failure envelope as shown in Figure 7.4
Example of Mohr Circle Plot, noting:
(a) The centre of Mohr circle must be on the abscissa and is given by (σ1,f + σ3)/2;
(b) The radius of such circle is (σ1,f - σ3)/2;
(c) Angle of internal friction is the angle of the Mohr-Coulomb failure envelope (failure
line);
(d) The failure line intersects with ordinate at the cohesion value.
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Figure 7.4 Example of Mohr Circle Plot
nt
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Table 8. 8 Format Report for Simple Triaxial Test
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Applied Principle
Confining Internal
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Specimen Stress at stress at Correlation

Pressure, Cohesion Friction
No. Failure Failure Coefficient
σ3 Angle
σa,f σ1,f
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2
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[kPa] [kPa] [kPa] [kPa] [°] [R ]

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8.7.15 Using Laboratory Test Results For Estimating Structural Layer Coefficients
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Notes:
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The minimum Retained Tensile Strength (%) requirement should be 75%.

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The following minimum compaction requirements are recommended:

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Material Type BSM3 BSM2 BSM1
Percentage of Modified AASHTO

> 97% > 100% > 102%
compaction T180
 The material passing the 0.075mm sieve to be >2% for BSM-emulsion and >4% for
BSM-foam.
 The maximum recommended addition of cement (active filler) is 1% by mass.
 Materials with a Plasticity Index > 10 to be pre-treated with hydrated lime to reduce
the PI to <6.
8.7.16 Proforma Report Sheet For Its Testing

The report sheet shown below may be used for all ITS tests, regardless of whether the tests
were carried out for mix design purposes or for testing field samples.
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8.7.17 Laboratory Equipment Requirements
1 Laboratory Equipment For Soils Testing
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2 Additional Laboratory Equipment for Cement or Lime Stabilisation
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3 Additional Laboratory Equipment for Bitumen Stabilisation
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END OF PART
Part 09: Recycled Aggregate for Roadworks
9 RECYCLED AGGREGATE FOR ROADWORKS ................................................................... 2

9.1 GENERAL ---------------------------------------------------------------------------------------------- 2
9.1.1 Scope 2
9.1.2 References 2
9.1.3 Definitions 3
9.2 SOURCE ----------------------------------------------------------------------------------------------- 3
9.3 APPLICATIONS -------------------------------------------------------------------------------------- 3
9.4 RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS ------------ 4
9.4.1 Requirements of Materials 4
9.4.2 Compaction of Fill Material 5
9.5 RECYCLED AGGREGATE FOR SUB-BASE MATERIAL ---------------------------------- 5
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9.6 RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN
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VILLAGE AREAS AND TEMPORARY ROADS ----------------------------------------------- 6
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9 RECYCLED AGGREGATE FOR ROADWORKS
9.1 GENERAL
9.1.1 Scope
1 The conditions of this part cover the requirements of recycled aggregate obtained from
demolition and excavation waste for use in roadworks.

Part 1, General
Part 3, Earthworks
Part 4, Unbound Pavement Materials
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9.1.2 References
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1 The following standards are referred to in this Part :
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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of
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Sodium Sulfate or Magnesium Sulfate
ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size
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Machine
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BS EN 933 Part 1 .......Determination of particle size distribution - Sieving method

Aggregates
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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size

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Machine
BS 1377 Part 4 ...........Methods of test for Compaction-related tests, California Bearing Ratio
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(CBR) of Laboratory-Compacted Soils

ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
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Aggregate
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BS 1377 Part 3 ...........Standard Test Methods for Classification tests, Liquid Limit, Plastic
Limit, and Plasticity Index of Soils
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BS EN 933 Part 3. ......Methods of test for Determination of particle shape - Flakiness index
BS EN 933 Part 4. ......Methods of test for Determination of particle shape - Shape index
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BS EN 933 Part 5 .......Methods of test for Determination of percentage of crushed and

broken surfaces in coarse aggregate particles.
BS EN 933-11:2009 ...Tests for geometrical properties of aggregates. Classification test for
the constituents of coarse recycled aggregate
BS EN 1097-2:2010...Tests for mechanical and physical properties of aggregates. Methods
for the determination of resistance to fragmentation
QS 29 / 2012 ..............The general Conditions For Recycled Aggregate Obtained From
Building Demolition
9.1.3 Definitions
1 Demolition Waste: Waste Material obtained from Excavated and/or demolished concrete
structures.
2 Concrete Demolition Waste : Waste Produced by demolition of concrete structures in

general.
3 Demolition Waste from Hard Concrete : Waste obtained from demolition of hard concrete
members such as columns, foundations and other mass concrete blocks.
4 Excavation Waste : Waste obtained from excavated materials.
5 Mixed Demolition Waste : Waste material obtained from both excavated and demolished
concrete structures.
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6 Mixed Aggregate : Recycled fine and coarse Aggregate combined together.
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7 Recycled Aggregate: a materials produced by the reprocessing of reclaimed construction
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and demolition waste. These include but are not limited to asphalt planings (i.e. the asphalt
layers of roads removed during roadworks, also known as RAP – Reclaimed Asphalt
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Pavement), fill, selected fill, granular subbase and rock from construction excavations.
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9.2 SOURCE
1 The debris pieces of blocks collected from road demolitions in various places should be
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stock piled at suitable location where different types of materials can be separated.
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2 The clean, tough, hard, durable, free from organic material and uncoated particles containing
no harmful materials in quantities sufficient to adversely affect construction works shall be
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stock piled separately according to the required nominal sizes. The material free from pieces
of steel, plastic and wood.
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3 The sources of aggregate should be regularly and thoroughly investigated to ensure the
quality of material is satisfactory. The aggregate shall be non-plastic and chemically stable.
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9.3 APPLICATIONS
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1 Carefully selected recycled aggregate can be used in many applications as shown below.
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(a) For Non-structural Concrete (Grade SRC 20) for backing of kerbs, channels, edging
and quadrant in road work.
(b) For manufacture of Hollow & Solid Blocks and Paving blocks for pedestrians.
(c) For Earth works related to roads.
(d) For Aggregate of sub-base materials.
(e) For Minor Roads of village areas and temporary roads.
2 Recycled materials from construction or a construction process, or from existing pavement

layers shall be separated according to type for processing. The separate processed
materials shall be stored in stockpiles of no greater than 4000 tons and quarantined for
testing and approval by the Engineer prior to use.
3 Samples shall be taken of the recycled aggregate constituents for classification by hand-
sorting the coarse aggregate particles in accordance with BS EN 933-11. The test shall be
carried out by a suitably trained laboratory technician who has demonstrated competence in
classifying the constituent classes in accordance with the test method.
4 Testing frequency shall be according to parts 3 and 4 of this section unless otherwise stated
by the Engineer.
5 Recycled aggregate shall be free from non-aggregate constituents such organics and shall
have a minimum amount of deleterious material which may affect its reuse.
6 The Percentage use of recycled aggregate shall not exceed the following:
(a) A maximum of 50% of recycled fine, and/or coarse and/or mixed aggregates whether
obtained from Concrete or mixed waste can be used for concrete works of less than
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20 MPa strength or any other construction works but not for asphalt layers.
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(b) It is not allowed to use recycled Aggregate obtained from concrete or mixed demolition
wastes in asphalt mixes. Only Recycled Aggregate from excavated material can be
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used in asphalt mixes.
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(c) A maximum of 100% of recycled aggregate obtained from excavated material can be
used in any of the above mentioned construction works.
9.4
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RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS
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9.4.1 Requirements of Materials
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1 Recycled material shall be tested according to the relevant parts of BS 1377 and shall be
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within the limits of following table:

Table 9.5
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Specifications of Recycled Aggregate for use in

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Earth Works Related to Roads

General Fill
Selected Fill
Requirement (Filling on low level
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( Sub-grade)
areas)
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Grading Standard Standard

Particle Size Less than 75mm Less than 75mm
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Organic Material (%) 2 max 2 max

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Liquid Limit (%) 40 max 35max

Plasticity Index (%) 11 max 10 max
Material Passing 0.075 mm (%) 40 max 35 max
Water Soluble Salts (%) 5 max 5 max
Acid Soluble Salts (%) 10 max 10 max
Soaked CBR Value - More than 15
Swell (%) - 2 max
Tree and Plant Stumps Free Free
Perishable Materials Free Free
Materials Subject to Spontaneous
Free Free
Combustion
Material From Sabkha and Marshes Free Free
9.4.2 Compaction of Fill Material
1 All Fill materials shall be placed in loose layers within the effective range of compaction of
the approved plant. The maximum permissible loose layer thickness shall be limited to
200mm.
2 The fill material shall be watered and mixed as necessary to ensure that prior to compaction,
the moisture content of the whole layer ±3% of the optimum moisture content obtained at the
laboratory compaction test (LCT). The compaction of layer shall continue until a density of at
least 95% of the maximum dry density of LCT.
3 No layer shall be covered by the next layer until it has been tested, inspected and approved
by the Engineer.
9.5 RECYCLED AGGREGATE FOR SUB-BASE MATERIAL
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1 The following table illustrates the material requirements for unbound materials for roadworks.
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Table 9.6
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Requirements of Recycled Aggregate for Roadworks Unbound Layers
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Raw Materials Production
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Requirement Aggregate
Fine Aggregate Coarse Aggregate
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Sub-Base
Grading Standard Standard Class C
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Particle Size Less than 4.75mm More than 4.75mm

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OR Less Than 4.0mm More than 4.0mm

Organic Material (%) 0.5 max Free Free
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Liquid Limit (%) –material

-
passing 0.425 or 0.500mm 25 max 25 max
Plasticity Index (%)–material
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-
passing 0.425 or 0.500mm 6 max 6 max
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MaterialPassing0.075mm (%) - - -
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Water Soluble Chlorides (%) - 1.0 max 1.0 max

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Acid Soluble Chlorides (%) - 2.0 max 2.0 max

Water Soluble Sulphates (%) - 1.5 max 1.5 max
Acid Soluble Sulphates SO 3(%) - 3.0 max 3.0 max
Soaked CBR Value - - 80 min
Swell (%) - - 1.0 max
Tree and Plant Stumps - Free Free
Perishable Marshes - Free Free
Materials subject to
- Free Free
Spontaneous combustion
Material from Sabkha and
- Free Free
Marshes
Clay Balls Free Free Free
Ratio of Passing 0.075mm &
66 - -
0.425mm (%)
Flakiness Index (%) - 35 max 35 max
Raw Materials Production

Requirement Aggregate
Sub-Base
Elongation Index (%) - 40 max 40 max

Los Angeles Abrasion (%) - 40 max 40 max
Soundness - magnesium
- 20 max 20 max
sulphates, 5 cycles (%)
Sand Equivalent Value - - 25 min
2 Mix Designs
(a) The recycled aggregate shall be used in aggregate sub-base and base courses. The
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fine and course aggregate shall be combined proportionately in order to achieve the
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following class of grading:
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Table 9.7
Gradation of Recycled Aggregate for use in Subbase Layers
nt Percentage Passing
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BS EN Sieve (mm) ASTM Sieve (mm) (by Weight)
Class C
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63.0 63.0 -
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- 50.0 -
40.0 37.5 -
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- 25.0 100
20.0 19 90-100
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10.0 9.5 50-85

4.0 4.75 35-65
2.0 2.36 25-50
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0.500 0.425 15-30

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0.063 0.075 5-15

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3 Screening and Mixing

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(a) Screening is required for recycled materials used in the road base and sub base to
ensure that the designated gradation is attained.
(b) Central Mixing plant is required for the mixing of materials.
9.6 RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN

VILLAGE AREAS AND TEMPORARY ROADS
1 Recycled Aggregate for use in Asphalt layers of temporary and minor roads in village areas
shall be reclaimed from excavated natural soil which is mechanically and chemically stable
and of specifications in the following table:
Table 9.9
Specification of Recycled Aggregate for use in
Asphalt Layers for Village and Temporary Roads
Recycled Aggregate
Requirement
Grading Standard Standard
Particle Size Less than 2.36 mm More than 2.36mm
Organic Material - including wood and materials
0.5 max 0.5 max
prone to disintegration (%)
Water Absorption –Saturated surface dry (%) 2.0 max
Liquid Limit - -
Plasticity Index (%) 4 max -
g
MaterialPassing0.075mm (%) - -
in
Acid Soluble Chlorides (%) 2.0 max 2.0 max
Acid Soluble Sulphates SO 3 (%) 3.0 max 3.0 max
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Materials subject to Spontaneous combustion - Free
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Materials from Sabkha and Marshes - Free
Clay Balls Free Free
Flakiness Index (%) nt - 35 max
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Elongation Index (%) - 40 max
Los Angeles Abrasion (%) - 40 max
&
Crushing Value (%) 25 max

Soundness - magnesium sulphates, 5 cycles (%) 18 max
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Sand Equivalent Value 30 min -

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2 The different sizes of material shall be separated by screening and re-combined together to
produce the all-in Recycled crushed aggregate, which shall achieve the following grading
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limits :
Table17.8
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Gradation of Recycled Crushed Aggregate for use in

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Asphalt Layers for Village and Temporary Roads

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BS EN Sieve (mm) BS Sieve (mm) Percentage Passing (by weight)

63.0 50.0 100
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40.0 37.5 95-100

20.0 19.0 60-80
10.0 9.5 40-60
4.0 4.75 25-40
2.0 2.36 15-30
0.500 0.600 8-22
0.063 0.075 5-12
3 Recycled aggregate for use in Asphalt layers of minor roads in village areas and temporary
roads shall be non–plastic.
4 The material shall wet during transporting and spreading in order to avoid segregation.
END OF PART
Part 10: Vehicle Crash Barriers
10 VEHICLE CRASH BARRIERS ....................................................................... 2
10.1 GENERAL REQUIREMENTS ........................................................................ 2

10.1.1 Scope 2
10.1.2 References 2
10.1.3 Performance Requirements 3
10.1.4 Submittals 3
10.1.6 Maintenance 5
10.2 STEEL WIRE ROPE BARRIERS .................................................................. 5
10.2.1 General 5
10.2.2 Component Ropes 5
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10.2.3 Tail Rope 6
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10.2.4 Safety Check Rope 6
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10.2.5 Posts 6
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10.2.6 Anchorage Frames 7
10.2.7 Other Components 7
10.2.8 Installation
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10.3 TENSIONED CORRUGATED BEAM SAFETY FENCE ................................ 9
10.4 UNTENSIONED CORRUGATED SAFETY FENCE .................................... 10

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10.5 OPEN-BOX BEAM SAFETY FENCE ........................................................... 11

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10.6 TENSIONED RECTANGULAR HOLLOW SECTION SAFETY

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FENCE ......................................................................................................... 12
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10.7 MARKERS FOR BARRIERS ....................................................................... 12

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10.8 CRASH CUSHIONS AND TERMINALS ...................................................... 12

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10.9 VEHICLE BARRIER UNITS (VBU) .............................................................. 13

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10.10 TEMPORARY CONCRETE BARRIERS ...................................................... 13

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10.11 ALUMINIUM BRIDGE PARAPET ................................................................ 14

10 VEHICLE CRASH BARRIERS

10.1.1 Scope
1 This section of the specification covers the supply, installation and foundation requirements
of the following representative types of vehicle crash barriers. The definition of each type of
barrier is given in the relevant section of the specification.
(a) steel wire rope barriers.

(b) tensioned corrugated beam safety fence
(c) untensioned corrugated beam safety fence
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(d) open box beam safety fence
(e) tensioned rectangular hollow section safety fence
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(f) permanent concrete barriers
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(g) temporary concrete barriers
(h) aluminium bridge parapet.
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2 This section of the specification does not cover the design criteria for deciding on the type of
barrier to be applied in a particular situation.
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3 Related Sections and Parts

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This Section
Part 12 Fencing
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Section 5 Concrete
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10.1.2 References
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BS 4............................Structural steel sections

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BS 302........................ Wire ropes for cranes, excavators and general engineering purposes
BS EN 13411-1 ..........Specification for Thimbles for wire ropes
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BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
BS 970........................Wrought steels for mechanical and allied engineering purposes
BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
BS 1490......................Aluminium and aluminium ingots for engineering purposes
BS EN ISO 2081 & BS EN ISO 2082, Electroplated coatings of cadmium and zinc on iron
and steel
BS EN 10264..............Round carbon steel wire for wire ropes
BS 3416......................Bitumen based coatings for cold application
BS EN 1011................MIG Welding of aluminium and aluminium alloys
BS 4320......................Metal washers for general engineering purpose
BS 4464......................Spring washers for general engineering and automobile purposes
BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
BS 6579......................Safety fences and barriers for highways
BS EN 1317................"Highway parapets for bridges and other structures. Part 1.

Specification for vehicle containment parapets of metal construction
BS EN 10025..............Hot rolled products of non-alloy structural steels - Technical delivery
conditions.
DTP, Manual of contract documents for highway works - volume 1 specification series 400
DTP, Manual of contract documents for highway works - volume 3 standard details
ASTM D 1248 .............Specification for Polyethylene Plastics Moulding and Extrusion

Materials US, Department of Transportation Research Report NCHRP,
No. 230.
ISO 9002 ....................Quality assurance system for production and installation
10.1.3 Performance Requirements
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1 The vehicle crash barriers shall present a continuous smooth face to an impacting vehicle so
that the vehicle is redirected without turning on its side or rolling over to a course that is
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nearly parallel to the barrier face and with a lateral deceleration which is tolerable to the
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vehicle occupant. The vehicle shall be redirected without rotation about either its horizontal
axis (spinning out) or vertical axis (overturning) and the rate of lateral deceleration shall be
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such as to cause minimum risk of injury to the passengers.
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2 The vehicle shall be directed so that no part of the vehicle crosses the line parallel with and
4 m from the original alignment of the traffic face of the fence or barrier within a distance of
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10 m from the last point of initial impact in the direction of the adjacent traffic flow.
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3 On impact the safety fence or barrier shall contain and redirect a vehicle of a certain mass
travelling at a certain velocity at an angle of incidence of 20 degrees to the fence or barrier.
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4 The level of vehicle containment shall be lower, normal or higher as designated, with the
following value for vehicle mass and vehicle speed.
Containment Vehicle Mass, kg Vehicle Speed, km/h
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Normal 1500 113

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Lower 1500 80
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Higher 5000 80
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The centre of gravity of the test vehicle prior to impact shall be 500 mm above the ground.
5 All the components of a vehicle crash barrier shall be designed to achieve a serviceable life
of not less than 20 years except for the use of temporary concrete barriers where the nominal
service life shall not be less than 10 years.
10.1.4 Submittals
1 The Contractor shall submit details of previous installations of the vehicle crash barrier over a
10-year period, indicating the system, its location and the type of highway.
2 For the particular crash barrier system proposed, the Contractor shall submit a detailed
report giving the results of vehicle impact tests, and may include photographs and video
recordings. The report shall be from an internationally recognised laboratory approved by the
Engineer. The report shall describe in detail the arrangements for the test including vehicle
weight, speed, impact area, full details of the test vehicle guidance and measuring systems
and speed measurements. The report shall include photographs showing the results of the
test. The report shall give full details of the actual vehicle speed, approach angle, vehicle
interaction and fence movement of vehicle and roll, yawl and pitch of the vehicle movement
after exit from safety fence. The report shall include details of the safety fence damage and
the vehicle damage.
3 Crash cushions and terminals. The Contractor shall make a detailed technical submission
that will include drawings indicating the layout for the system at different locations. The
Contractor shall also submit design calculations for the system for head on impact and side
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impact. These calculations shall indicate the reduction in G force or all vehicles of specified
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weight and speed. The submission shall contain the precise specification of the individual
elements of the system, installation procedures, fixing details and fully dimensioned scale
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layout drawings. The Contractor shall submit reports from the highway authority where the
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particular barrier system has been used showing details of vehicle collisions and the results
of such collisions.
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4 The Contractor shall submit calculations to show that post foundations can withstand an
overturning moment of 6.0 kNm.
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5 The Contractor shall submit full technical details of the safety fence system proposed
including post to beam connection details of beam joints and post to beam connection details
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of posts, and details of tensioning assembly.

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6 The Contractor shall submit calculations showing the required size and details of the lifting
eyes for permanent and temporary concrete barriers for the designated barrier details.
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1 Vehicle crash barriers shall have been tested by an approved Testing establishment such as
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the UK Transport and Research Laboratory. The Engineer shall decide what is an approved
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Testing establishment.
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2 The manufacturer shall operate an approved quality assurance system complying with ISO
9002 for the fabrication and supply of components used in the vehicle safety barriers. Only
components complying with the manufacturer’s specifications may be used.
3 The supplier shall submit certification showing that tensioned rectangular hollow section
safety fence systems have been tested in accordance with the requirements of the UK
Transport and Research Laboratory.
4 Crash cushion and terminal systems shall have been satisfactory tested following the
procedures set down in the US Department of Transportation Research Report NCHRP, No.
230. The installation of the system shall be supervised by a representative of the
manufacturer with a minimum of five years of experience in the use of the system.
10.1.6 Maintenance
1 For vehicle crash barriers, crash cushion and terminal systems the Contractor shall supply:
(a) four copies of the installation and maintenance manual

(b) a relevant spare parts list for the system showing the recommended set of spare parts
needed to restore one system to its original condition after a head on impact
(c) if specified elsewhere in the Contract the Contractor shall supply spare parts for the
system
(d) current prices of spare parts
(e) profile of a local agent
10.2 STEEL WIRE ROPE BARRIERS
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10.2.1 General
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1 Steel wire rope safety fence barriers shall be supplied and installed in accordance with the
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designated dimensions and details shown on the contract drawings. The post details,
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spacing, anchorage, size shapes and general layout shall be as per the details shown on the
contract drawings.
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2 Wire rope barriers shall consist of either two or four, tensioned, galvanised, steel-wire ropes.
The type of system to be specified shall be as shown on the contract drawings.
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3 Four wire rope barriers shall consist of two upper ropes located in a slot at the top of the steel
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posts and two lower ropes interwoven along the fence between each pair of ropes. The
ropes shall be joined and tensioned by means of screws at the designated intervals.
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4 The ends of the ropes shall be attached to anchor blocks and embedded in the ground.
Steel posts may be located in the ground either as driven posts or in concrete footings. In the
case of any obstruction, the Contractor shall propose an alternative steel post, surface
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mounted to the equivalent of strain. Steel posts shall be removable and replaceable.
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5 The supply and installation of steel wire safety fence barriers is to be carried out in
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accordance with BS 6579, except as modified herein.

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10.2.2 Component Ropes
1 Component ropes shall consist of steel wire ropes fitted with end terminals.
2 The rope shall be 19 mm diameter, 3 x 7 (fill) galvanised wire rope generally to BS 302: Part
1 with a minimum breaking force of 173.6 kN. All wire used in the rope shall be to BS EN
10264 galvanised normal duty. Various galvanised wire finishes may be used by agreement
with the Engineer.
3 The rope shall be prestressed by applying a cyclic loading until all initial extension has been
removed. After prestressing the rope will exhibit a minimum modulus of elasticity of 8300
kg/mm2 based on an area of 283 mm2.
4 The complete component rope shall have terminals, one end right-hand thread and the other
left-hand thread.
5 The fittings shall be attached to the rope whose length measured over the extreme ends of
the threaded portion of the fittings shall be 153.35 m, -0/+25 mm. Other special lengths of
rope with identical construction may be detailed as necessary for specific applications.
6 All threaded terminals shall be made from steel to BS 970: Part I Grade 65SM13 and either
cadmium plated to BS EN ISO 2081 & BS EN ISO 2082 class B or alternatively galvanised to
BS EN ISO 1461.
7 A test will be carried out to destruction on a threaded terminal test piece consisting of a
terminal and a length of rope such that the minimum test length is 600 mm. This assembly
shall have a minimum breaking force of 164.6 kN.
10.2.3 Tail Rope
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1 Tail ropes shall be short lengths of rope fitted with threaded terminals at both ends that are
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used to connect component ropes to anchors. Tail ropes shall be supplied to the site
prefabricated.
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2 Tail ropes are of identical construction and specification to the component ropes but of
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different overall length. These ropes must also be prestressed.
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3 The length of the fitted rope measured over the extremities of the threaded portions of the
screwed terminals shall be 6 m  10 mm.
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4 Tail ropes shall be terminated in one of two ways using identical terminals to those specified
for component ropes: with right-hand terminations on both ends, or with a right-hand at one
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end and a left-hand termination at the other.

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10.2.4 Safety Check Rope

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1 Safety Check Ropes are steel wire ropes fitted with end terminations. The rope itself shall be
8 mm diameter 6 x 19 (9/9/1) IWRC galvanised wire rope to BS 302 with a minimum breaking
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force of 40.3 kN. All wires used in the rope shall be to BS EN 10264 grade normal duty,
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galvanised to class 'A' finish.

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2 The rope shall have a galvanised heart-shaped thimble to BS EN 13411-1 capable of

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accepting a 38 mm diameter pin fitted by using a pressed ferrule on one end and a forked
terminal on the other end.
3 The length of the rope between the centre of the 38 mm pin hole and the 9 mm pin hole shall
be 1.8 m –0/+20 mm.
10.2.5 Posts
1 There are three types of posts with variations for embedded style or surface mounting: line,
deflection and surface.
2 All posts shall be manufactured from 6 mm section cold rolled mild steel plate to BS EN
10025 grade Fe 50A, having a minimum yield strength of 355 N/mm2. All posts shall be
galvanised to BS EN ISO 1461. Dimensions and tolerances of the types of posts shall be as
designated.
3 Post foundations and anchor blocks shall be as per the dimensions and details designated by
the supplier.
10.2.6 Anchorage Frames
1 A range of anchorage frames must be available for various locations and applications. These
are: on the median, verge and for end/intermediate and embedded/surface mounted fixings.
The anchorage frames shall comply with the requirements of clause 4.3 of BS 6579.
2 End anchorage frames shall be constructed from weldable structural steel as defined in BS
EN 10025 Grade Fe 430A with steel plate to section 4, and steel bar to section 6. Rolled steel
channel to BS 4. All materials shall be galvanised to BS EN ISO 1461.
3 Intermediate anchorage frames are double sided frames. All materials and finishes shall be
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as defined above.
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4 The intermediate anchor frames may be surface mounted.
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10.2.7 Other Components
1
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Sockets for post foundation shall be constructed from 3 mm steel to BS EN 10025 Grade Fe
430A. Galvanised to BS EN ISO 1461.
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2 Excluders shall be produced from high-density polyethylene type iii class C Cat 4, ASTM D
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1248
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3 Rigging screws shall be used to connect component ropes together and component to tail
ropes. The rigging screws shall be the body of a rigging screw manufactured to BS 4429.
Except for the threads which are to be right and left hand M24 x 3-7H. Each rigging screw
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shall be hot dipped galvanised to BS EN ISO 1461.

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4 Steel pins used in the fork terminal on the safety check rope shall be made from BS 970
Grade 045M10.
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5 Split cotter pins shall be in stainless steel 2.5 mm x 16 mm to BS 4320 and shall have a
retaining pin.
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6 Nuts used to secure the threaded rope terminal to an anchor frame shall be M24 thread in
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zinc electroplated condition. Steel washers shall be M 24 to BS 4320 and fitted over the
threaded terminal and between the nut and anchor frame.
7 Locating hooks shall be made in stainless steel to BS 970 Part I. Nuts (for hooks) shall be M6
to BS 3692 Grade A2.
8 Caps for posts shall be high-density polyethylene Type III class c cat 4, ASTM D 1248
9 Ordinary thimbles shall be size 9, fitted to safety check rope made to BS EN 13411-1.
10 The fork terminal shall be fitted to the safety check rope shall be made to BS 970 Grade
45 M10.
11 All ropes, terminals, rigging screws, posts and anchor frames are to be clearly marked with
the manufacturers identification and the date of manufacture and the standard of
construction.
10.2.8 Installation
1 Steel wire ropes safety fences shall not be used where
(a) the length of fence at full height would be less than 37.5 m
(b) on horizontal kerb at radius less than 600 m
(c) on vertical sag curves of radius less than 300 m
(d) on medians having a width of less than 3.14 m
(e) where the height of any kerb at the edge of the adjacent surface exceeds 100 mm
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(f) where high mast lighting columns are situated within 10m of the edge of the paved
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surface
(g) where the fence has to be connected to any other fence or building
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2 All components shall be suitably protected and supplied in packaging that prevents any
permanent damage particularly to threaded components. Damage to metallic coating shall
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be prevented by appropriate means. Any damage found on inspection prior to installation
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shall be made good to the satisfaction of the Engineer.
3 Component ropes and tail ropes shall be supplied on reels with a bar of diameter not less
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than 450 mm.

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4 Ropes shall not be twisted or kinked.

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5 Driven line posts shall be installed to the alignment and level shown on the drawing without
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damage to the slot on the top of the post.
6 The top of the post shall be capped with a black polypropylene excluder.
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7 The length of the line rope between any two adjacent anchors shall be not greater than
627m.
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8 Tensioning between any two limits shall not proceed until the Engineer is satisfied that each
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limit is anchored sufficiently securely to resist the load effects due to tensioning.
9 The tension shall be measured using a device approved by the Engineer.

10 The ambient air temperature shall be noted at the time of tensioning and adjusted as follows;
ROPE TENSION kN AMBIENT TEMPERATURE C

14.00 45
16.75 40
19.50 35
22.25 30
25.00 25
27.75 20
30.50 15
33.25 10
g
36.00 5
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10.3 TENSIONED CORRUGATED BEAM SAFETY FENCE
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1 Except as modified herein, tension corrugated beam safety fences shall comply with the DTP
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Manual of Contract Documents for Highway Works Specification - Volume 1, specification
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series 400.
2 Tensioned corrugated beam safety fences are for use on high speed roads at the road edge
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or on the central median in one of the following forms:

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(a) Single sided for road edges.

(b) Double sided for medians.
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(c) Dual single sides for medians .

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3 In the event of an accident, the support post shall give away while the safety fence remains in
tension absorbing the impact energy while protecting the traffic on the opposite carriageway.
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The angle of deflection shall be reduced and as the vehicle decelerates it shall be redirected
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towards the carriageway.

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4 The barrier shall consist of a strong corrugated steel beam section mounted and tensioned
on steel universal posts. End posts shall be set in concrete and intermediate posts can be
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driven or set in concrete.
5 Surface mounted posts may be used where there are obstructions. In all cases the end posts
which are attached to barriers must be set in concrete.
6 The layout and the positioning of the barrier shall be as shown on the contract drawings. The
details and sizes and spacing of the various components shall be as shown on the contract
drawings.
7 The height of the centreline of the barrier shall be 610 mm above the edge of the carriageway
unless shown otherwise on the contract drawings.
8 There is no maximum length for installation. Where the line of the barrier is interrupted for an
obstacle or gap, additional end anchorages shall be provided.
9 Where a barrier protects an individual short obstacle the barrier should extend from at least
30 m in front of the obstacle to at least 7.5 m or more beyond it. A minimum clearance of
1.2 m behind the barrier shall be allowed for deflection.
10 Circular installations shall be at a radius of not less than 120 m. Tighter radii than this shall
not be used without the written approval of the Engineer.
11 Tensioners shall consist of two longitudinal bulbs installed in brackets and shall be positioned
in intervals along the barrier and bolted to the corrugated beam.
12 Beams shall be connected by lap joints using screws nuts and washers. Beams shall be
spliced by lapping with the edge facing away from the direction of traffic. Longitudinal
clearance between screws and slotted holes in the beams shall be removed by prising apart
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the beams. The nuts shall be tightened to a torque approved by the supplier.
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13 Tensioning between any two limits shall not proceed until the Engineer is satisfied that each
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limit is anchored sufficiently securely to resist the load effects due to tensioning. Tensioning
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shall be carried out strictly in accordance with the system manufacturer’s recommendations.
Adjustments to the tensioning shall be made for the ambient temperature at the time of
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tensioning strictly in accordance with the system manufacturer’s recommendations.
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14 The beam shall be completely formed, punched with holes for mounting and splicing and
ready for assembly when delivered. It shall be uniform corrugated section straight or curved
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sections, galvanising shall be carried out after fabrication and each element and end sections
shall be marked at the point of fabrication with the manufacturer’s name or trade mark,
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gauge and heat ( steel batch ) number and with the coating lot referenced.
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15 The barrier system shall be supplied with all required terminals and approach flares for the
particular installation situation.
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16 Safety barriers shall be erected to present a flowing alignment, with the alignment in plan not
more than ± 30 mm from the prescribed alignment and no deviations in a 10 m length by
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more than ± 15 mm from the prescribed alignment. The height of the beam shall not depart
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from the prescribed height by more than ± 30 mm nor deviate in any 10 m length from the
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prescribed height by more than ± 10 mm.

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10.4 UNTENSIONED CORRUGATED SAFETY FENCE
1 Untensioned corrugated safety fences shall meet the requirements of the tensioned
corrugated safety fence except as modified herein and the fence shall not be tensioned.
2 Untensioned corrugated safety fences can be used in low-speed situations to prevent

vehicles crossing median and for protection at the verge.
3 Beams shall be shaped so that there are no sharp edges protruding into traffic. Beams shall
be connected by lap joints made in the direction of the traffic flow. The beams shall be
formed from a 3 mm steel strip to give a corrugated cross-section. On curves less than 45 m
radius, the beam shall be provided in preformed curves, internal or external, without any
reduction in strength.
4 At terminations, the end rails shall be sloped down at a slope of approximately 1 in 6 to

terminate just above ground level. Anchorage shall be provided by an end post set in
concrete. Unless otherwise designated the centreline of the beam shall be 610 mm above
the edge of the carriageway or hard shoulder.
10.5 OPEN-BOX BEAM SAFETY FENCE
1 Open box beam safety fences shall meet the requirements of the DTP - Manual of contract
documents for highway works - volume 1 specification series 400 except as modified herein.
2 The open-box beam barrier shall be used on high-speed roads where a stiffer barrier than
the tensioned corrugated beam is required. The open-box barrier can be used for a double
sided installation in a median.
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3 The layout, positioning, post spacing and all dimensions of the system shall be as
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designated.
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4 The systems shall comprise a main traffic section rail element with a traffic face 150 mm
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wide. This shall be ground mounted on relatively weak Z-section posts or with hexagonal
energy absorbing brackets bolted to a reinforced concrete wall or bridge pier. The traffic face
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shall be set to a height of 610 mm at the centreline of the rail.
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5 There is no limit to the length of the installation, but end rails shall be taken down to ground
level and bolted to end posts to form anchors which are set in concrete.
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6 Where the installed barrier exceeds 100 m in length, expansion joints are to be inserted in
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the main rail.

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7 The standard section length shall be 4.8 m unless otherwise designated, and this value shall
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be used on curves of radii down to 335 m.
8 For radii between 335 m and 107 m special fish plates shall be used.
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9 For radii between 107 m and 50 m, 2.4 m rail lengths shall be used with special fish plates.
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10 Z-section intermediate posts shall be connected to the main rail by shear bolts and clamp
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plates into the back of the rail section.
11 Rail sections shall be butt jointed together connected by fish plates and bolted in connection.
12 Where a non-standard situation arises in the use of the crash barrier, the supplier shall obtain
recommendations from the UK Transport Research Laboratory.
13 In particularly hazardous locations where vehicles with a high centre of gravity are in use, the
open box barrier may be installed to a double height with two protective rails. The horizontal
centreline of the second rail shall be positioned 1 m above the adjacent carriageway. The
two box section rails shall be connected together with vertical straps or a single shear bolt in
the centre of each connection of the rails to longer intermediate posts.
10.6 TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE
1 Tensioned rectangular hollow section safety fences shall be installed as designated. The
position, layout dimensions and details shall be as designated.
2 The barriers shall be used where protection is required for bridge piers lighting columns and
other obstructions.
3 The size of the rectangular hollow section shall be 100 mm wide x 100 mm high or
100 mm wide x 200 mm high.
4 The minimum recommended curve for the barrier shall be 120 m radius. Tensioners shall be
fitted at a maximum spacing of 70.5 m and the first tensioner shall be within 50 m of the
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anchorage.
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5 When supplied the system shall include a detailed packing list with each component
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referenced and clearly marked to the standard of manufacture and the manufacturer’s name
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and date of manufacture.
10.7 MARKERS FOR BARRIERS nt

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1 To ensure that the vehicle crash barriers are clearly delineated, reflectorized markers shall be
fixed to the barriers. The work shall consist of the fabrication supplied and fixing of
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reflectorized markers to vehicle crash barriers and other road side obstructions.
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2 Reflectorized markers shall consist of two retro-reflective faces of minimum area 4000 mm2
on a weather proof durable backing capable of being fixed to the barrier. All metal fixings and
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fittings shall be galvanised or stainless steel and approved by the Engineer.

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3 Reflectorized faces shall consist of a minimum of 210 glass beads set in a 3 mm thick tough
durable plastic backing. The two faces of the marker shall be of the colour specified in the
Qatar Traffic Manual unless shown otherwise in the drawing or instructed otherwise by the
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Engineer.
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4 Reflectors shall be fixed to safety barriers and other structures where designated. Stainless
steel fixings complying with BS EN ISO 3506 grade A4 shall be used to attach markers to
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concrete. Plastic isolation washers shall be used if the marker is galvanised.
10.8 CRASH CUSHIONS AND TERMINALS
1 Where designated, permanent or portable energy absorbing terminal systems shall be

provided for protection of traffic as shown on the drawings.
2 Proposed systems shall have a proven record of satisfactory performance of at least five
years in a number of locations.
3 The system shall be able to withstand head on and side impacts within the specified design
criteria. The system shall have the performance characteristics of a conventional metal
beam guard rail for strength durability and redirectional properties.
4 All of the components and materials of the system shall be suitable for use in the climatic
conditions of Qatar and shall not be liable to damage or deterioration in high temperatures or
by prolonged exposure to direct sunlight.
5 The system shall be such that most major components can be reused after a typical impact.
6 All metal work used in the system shall be galvanised or stainless steel.
7 All concrete used in the system shall meet the requirements of Section 5.
8 No work or fabrication of the system or ordering of the materials shall be carried out until the
Engineer has given formal approval in writing to the Contractor’s detailed submission.
10.9 VEHICLE BARRIER UNITS (VBU)
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1 Vehicle barrier units and their foundations shall be as per the details and dimensions shown
on the drawings.
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2 Vehicle barrier units shall be mass concrete of grade C25
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The barriers shall be cast in-situ in nominal 6 m length units unless designated otherwise.
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4 All the concrete materials and procedures including any steel reinforcement for the barriers
shall comply with Section 5.
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5 Forms shall be smooth and tight-fitting which can be held rigidly to the line and grade during
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the placing of concrete.

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6 At the option of the Contractor, the barriers may be precast in sections not exceeding 6 m in
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length. In such cases the barrier shall be reinforced to ensure that information technology can
be safely handled and have 2 no. lifting eyes of galvanised steel cast in at the top. The
method of casting, handling and placing of barrier sections shall be proposed by the
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Contractor for approval by the Engineer.

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7 The joints between the barriers shall be as per the details shown on the drawings.
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8 Vehicle barrier units shall be cast onto blinding concrete laid onto compacted subgrade
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10.10 TEMPORARY CONCRETE BARRIERS
1 Temporary concrete barriers shall be used for traffic management at road diversions or
detours where there is slow moving traffic.
2 Temporary concrete barriers shall be as per the designated detailed dimensions. The
barriers shall be either double or single sided.
3 The barriers shall be cast in nominal 6 m length units unless otherwise designated.
4 Each barrier shall have cast in at the top two lifting eyes of galvanised steel.
5 Where adjacent barriers are put together two galvanised steel wire eyes shall be cast in to
the ends to allow a steel pin to be placed through the eyes and into the road surface to
secure the barrier laterally.
6 The Contractor shall propose the reinforcement in the precast barriers which shall be
adequate to resist the forces and moments induced during lifting and handling.
7 All the concrete work including any steel reinforcement for the barriers shall comply with
Section 5 of this specification.
8 The method of casting, handling and placing of barrier sections shall be proposed by the
Contractor for approval by the Engineer.
10.11 ALUMINIUM BRIDGE PARAPET
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1 The aluminium alloy parapets for installation on the bridges and retaining walls shall be
designed to the requirements of BS EN 1317 "Highway parapets for bridges and other
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structures. Part 1. Specification for vehicle containment parapets of metal construction".
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2 The parapet shall be designed for normal level of containment as defined by the standard i.e.
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that required to resist penetration from the following vehicle’s impact characteristics:
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Vehicle Saloon Car
Mass 1500 kg
Height of centre of gravity 600 mm
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Angle of impact 2 degrees

Speed 113 km/h
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3 The parapet proposed for use shall be a three rail system of an established design the
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prototypes of which have been subjected to full scale dynamic testing. The parapet design
which shall therefore be considered exempt from further dynamic testing shall be taken from
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the list in Appendix G of BS EN 1317.
4 The parapets supplied to the project shall be certified by the supplier as a normal
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containment system complying with one of the following.

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5 That it complies in all respects with the design of parapet that successfully met the
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requirements of Clause 26.1 or 26.5 (concerning dynamic testing) of BS EN 1317 as

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appropriate.
6 That any modifications that have been made to the tested design comply with Clause 26.6 or
26.7 of BS EN 1317 as appropriate.
7 The parapet construction materials shall be as follows:

Extruded sections Aluminium alloy 6082-T6 to BS 1474
Castings Aluminium alloy LM6M to BS 1490
8 The finish of the parapets shall be high quality defect free mill finish and as cast finish for
extrusions and castings respectively.
9 All aluminium welds shall confirm to BS EN 1011 and the requirements of BS EN 1317.
10 All setscrews and nuts are to be stainless steel to BS EN ISO 3506 material grade A4.
Setscrews are to be strength class 80. Washer material is to be stainless steel to BS 1449:
Part 2 conforming to grade A4 or A2 as defined in BS EN ISO 3506.
11 Rail attachment and rail joint screws are to be M12 x 30 long hexagon head each complete
with one spring washer to BS 4464 type B, and one plain washer to BS 4320 form A.
12 Holding down bolts are to be M20 hexagon head bolts of sufficient length to give the
engagement required in BS EN 1317.
13 Bottom mesh fixing screws if required, are to be to the M8 long hexagon head set screws
each complete with one spring washer, two plain washers and one M8 nut where appropriate.
14 The holding down arrangement shall be in accordance with the requirements of BS EN 1317.
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15 Loctite grade 270 (or similar approved) to be applied on erection to all rail joint and rail
attachment setscrews. At the holding down bolts, contact between the stainless steel and
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aluminium baseplate shall be avoided by the use of a suitable "top-hat" insert manufactured
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from an inert material.
16
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Underside of baseplates are to be given at least two coats of an alkali resistant bitumastic
paint or pitch complying with BS 3416.
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17 Mesh, if required, shall be 10 gauge welded steel wire in accordance with BS EN 1317,
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where appropriate. It may be galvanised, or any other finish as directed by the Engineer.
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18 Rivets shall consist of Avdel drive rivets, code 5141 or 06 37 or similar approved. Where
there is no substantial backing Avdel chrobert rivets, code 1125 06 13 with sealing pins code
1182 06 07 or similar approved, shall be used.
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19 Full details of the proposed supplier with his technical specification in English covering
materials, main dimensions and sizes shall be submitted to the Engineer for approval before
the Contractor places an order.
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20 Two copies of detailed shop drawings shall be submitted and the Engineer's approval
obtained before manufacture is commenced.
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21 During erection, parapets shall be securely held in their correct position until all connections
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and fastenings are complete and the post fixings have attained adequate strength to the
Engineer's approval.
22 The finished parapets shall be true to line and level throughout their length.
23 Panels and members shall be free from twist, and posts shall be truly vertical.
END OF PART
Part 11: Kerbs, Footways and Paved Areas
11 KERBS, FOOTWAYS AND PAVED AREAS............................................................ 2

11.1 GENERAL ............................................................................................................... 2
11.1.1 Scope 2
11.1.2 References 2
11.1.3 Submittals 2
11.2 KERBS .................................................................................................................... 3
11.2.1 General 3
11.2.2 Materials and Manufacture 3
11.2.3 Laying 5
11.3 PRECAST CONCRETE PAVING BLOCKS ............................................................. 6
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11.4 LAYING PRECAST CONCRETE PAVING BLOCKS ............................................... 7
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11.5 PRECAST CONCRETE PAVING SLABS ................................................................ 8
11.6 CAST-IN-PLACE CONCRETE PAVED AREAS....................................................... 9
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11.7 BITUMINOUS PAVED AREAS ................................................................................ 9
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11 KERBS, FOOTWAYS AND PAVED AREAS
11.1 GENERAL
11.1.1 Scope
1 Highway kerbs, edging kerbs for footways and other paved areas. Precast concrete paving
slabs and precast interlocking concrete block areas.
2 Related Sections and Parts:

This Section
Part 3 Earthworks
Part 4 Unbound Pavement Materials
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Section 5, Concrete
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Section 13, Masonry
11.1.2 References
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BS 812........................Testing Aggregates
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BS 1377......................Methods of test for soil for civil engineering purposes

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BS 7533......................Code of practice for laying precast concrete units

BS 7533-3 ..................Laying precast concrete paving blocks
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BS EN 197-1 ..............Cement composition specifications and conformity criteria for

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comments cements
BS EN 1338................Precast concrete paving blocks
BS EN 1339................Concrete paving flags
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BS EN 1340................Concrete kerbs unit

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BS EN 12620..............Aggregates for concrete

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BS EN 12878..............Pigments for the colouring of building materials

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11.1.3 Submittals
1 The Contractor shall submit samples of the various types of concrete kerbs and other
pavement materials for approval by the Engineer before beginning the work.
1 Tests shall be carried out on the concrete mix before beginning manufacture of precast kerbs
and other items to ascertain the strength and surface finish requirements can be met. If the
required strength and surface finish are not obtained, the Engineer may order revisions to be
made in order to achieve the designated requirements.
2 The Engineer shall, at all reasonable times, have access to the place where paving blocks
and other items and their constituent materials are manufactured and stored, for the purpose
of examining and sampling the materials and finished blocks, inspecting the process of
manufacture and marking the blocks.
3 The laying of paving blocks shall comply with the requirements of the Code of Practice for
Laying Precast Concrete Block Pavements and BS EN 1338 except where otherwise
designated.
11.2 KERBS
11.2.1 General
1 The following are the types of precast kerbs to be constructed where designated together
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with associated channels, edgings and quadrants:
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(a) Non-mountable.
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(b) Dropped.
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(c) Flush.
2 nt
The dimensions and shapes of the different kerb types shall be as per the details in BS EN
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1340 unless otherwise shown on the drawings or designated in the contract.
3 The bedding and support for such units shall be as shown on the drawings.
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4 Except as modified in this Part, all precast concrete kerbs, channels, edgings and quadrants
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shall be hydraulically pressed complying with BS EN 1340.

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5 Kerbs shall be laid and bedded in accordance with BS 7533 on the concrete pavement slab,
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a mortar bed, the road base, or on a concrete foundation while it is still plastic or after it has
set. All precast units shall be backed with concrete as per the designated details.
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6 The use of cast-in-situ concrete for kerbs will not be permitted except with the express written
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approval of the Engineer.

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11.2.2 Materials and Manufacture

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1 Constituent concrete materials for kerbs shall conform to the requirements designated in
Section 5. Kerbs shall be prepared with a concrete mixture containing not less than 400
kg/m3 of sulphate resisting Portland cement.
2 Testing of concrete kerbs shall be carried out in accordance with the requirements of BS EN
1340.
3 The aggregate shall meet the designated requirements and conform to the following
gradation.
Table 11.1
Aggregate Gradation for Kerb Concrete
Sieve mm % Passing by Weight
19 100
13.2 76-100
9.50 60-80
4.75 40-60
2.36 22-42
1.18 12-32
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0.6 7-23
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0.3 4-15
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0.15 2-10
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0.075 0-2
4 nt
The 28-day compressive strength of the concrete shall be not less than 30 N/mm2
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determined on 150 mm cube specimens, and not less than 75 % of this figure after seven
days.
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5 Non-mountable kerb, dropped kerb, flush kerb and heel kerb elements shall only be precast
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from concrete produced in a fully automatic batching plant.

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6 Before approval of elements of commercial manufacture, cores shall be taken from a random
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sample to ascertain that the concrete strength is not less than 25 N/mm2 at 7 days.
7 Elements shall be manufactured to the designated dimensions as standard 900 mm lengths

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unless specified otherwise in the contract documents.

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8 Non-mountable and dropped precast kerbs shall be formed by elements 500 mm long where
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required to be laid in straight lines but may be reduced to 250 mm long where required to be
laid to curves, depending on the radii of the curves.
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9 The finished product shall be of solid appearance with clean planar faces, be free of
segregation, honeycombing, pits, broken corners or other defects and there shall be no
evidence of external rendering.
10 Bull-nosed and curved faces shall be of constant radius with a smooth change from radius to
straight.
11 Tolerances of manufacture shall be 3 mm in any one dimension and end faces shall be truly
perpendicular to the base.
12 Transverse strength requirements shall be assessed in accordance with BS EN 1338

appendix B. The loads at failure shall not be less than the appropriate value given in Table
11.1A.
Table 11.1A
Transverse strength of kerbs, channels and edgings
Depth as tested Width as tested Load at failure
(mm) (mm) (kN)
150 305 22.2
125 150 8.0
125 255 13.3
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50 255 5.1
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50 205 4.5
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50 150 3.3
Dropper kerbs
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125 255 to 150 10.3
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13 Water absorption requirements shall be assessed in accordance with BS EN 1338 appendix

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C. The water absorption shall not exceed the appropriate value given in Table 11.1B.
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Table 11.1B
Water absorption of kerbs, channels and edgings
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Water absorption in % by mass

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Kerbs, channels and quadrants Edgings

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3.0 3.6
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11.2.3 Laying
1 Elements shall be set on to the designated lines and grades. Under no circumstances shall it
be permitted for levels to be set by direct measurement from pavement layers.
2 Unless otherwise indicated, elements shall be laid either directly onto a wet-concrete base or
onto a sand/cement (3:1) mortar bedding, 25 mm thick, on a previously laid concrete base or
approved subbase. The dimensions of the base and concrete class shall be as designated.
3 After kerb units have been laid, a contiguous backing of concrete shall be poured for the
elements using steel forms, unless otherwise designated. Lateral resistance shall be
provided to the kerbs by placing dowel bars in the backing concrete in not more than 500mm
intervals.
4 No pavement layers shall be laid against kerbing until such time as the backing is completed,
backfilled and approved by the Engineer.
5 Joints between kerbs, shall have a width of 4 mm. These joints shall be filled completely with
fluid sand cement mortar approved by the Engineer and the joints shall be formed again.
6 Immediately after any concrete is in place, and for seven days thereafter, the kerbs, base,
and backing shall be fully cured and protected from drying out and against the harmful effects
of weather, including rain and rapid temperature changes. The method of protection shall be
subject to the Engineer's approval. The use of coloured curing membranes will not be
permitted. Concrete not properly cured and protected will be rejected and shall be removed
from the site.
7 At every 10 m interval movement joint 20 mm thick shall be formed through the concrete bed
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and backing. The joint filler shall be bitumen impregnated cork board. The filler shall extend
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through the kerb, bed, backing and channel, and shall be trimmed to the finished shape of
the kerb and channel.
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8 At access points, the kerbs, including the bed backing shall be dropped to show a face of
25 mm or as otherwise designated.
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9 At the termination of any kerb run, the end kerb section shall be sloped down to ground level,
if applicable, and angled away from the road at 30 degrees in accordance with BS 7533.
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10 All kerbs shall be thoroughly cleaned of all extraneous materials.

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11 Kerbs shall be laid within a tolerance of  3 mm, at each end of an element, to the designated
lines and grades.
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11.3 PRECAST CONCRETE PAVING BLOCKS
1 Standard rectangular precast concrete paving blocks shall have a work size length of 200
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mm and a work size width of 100 mm. Paving blocks of any other shape may be made
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provided they fit within a 295 mm square co-ordinating space. The preferred work size
thicknesses are 60 mm, 80 mm and 100 mm for all types of paving blocks.
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2 The actual sizes of the paving blocks as determined in accordance with BS EN 1338 shall not
deviate from the work size dimensions by more than the following tolerances:
Length  2 mm
Width  2 mm
Thickness  3 mm
3 The binder used in making the paving blocks shall be Ordinary Portland Cement, Sulphate
Resisting Portland Cement or Moderate Sulphate Resisting Portland Cement which complies
with BS 4027 or ASTM C150; respectively.
4 The aggregates used in making the paving blocks shall be Gabbro, and they shall comply
with section 5 of QCS.
5 The water used in the manufacturing of the blocks shall be of drinking quality or shall be in
conformance with section 5 of the QCS.
6 The pigments, which are used to give colour to the paving blocks, shall comply with BS EN
12878.
7 The average tensile splitting strength of 16 paving blocks tested in accordance with BS EN
1338 shall not be less than 3.6MPa and the strength of any individual block shall not be less
than 2.9MPa and the failing load not lower than 250N/mm.
8 The average water absorption of three tested samples shall not exceed 5% and no individual
block shall have a water absorption greater than 6%.
11.4 LAYING PRECAST CONCRETE PAVING BLOCKS
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1 The paving blocks shall be laid generally in accordance with BS 7533-3 and to a pattern
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2 A laying course consisting of fine aggregates (sand), which complies with the corresponding
grading requirement given in Table 11.2, shall be constructed. The fine aggregates shall be
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placed in a moist but not a saturated condition and shall be compacted so that a laying
course thickness of 50 mm approximately is formed. This sand layer shall be placed on a
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compacted aggregate subbase or base as indicated in the project specifications/drawings.
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3 The paving blocks shall be laid on the laying course and compacted using a plate compactor
with a plate area of not less than 0.25 m2, transmitting an effective pressure of not less than
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75 kN/m2 of plate at a frequency of vibration in the range of 75 Hz to 100 Hz.

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4 A maximum deviation for the block paving from design levels of  6 mm shall be maintained.
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5 The joints between the paving blocks shall be filled with dry jointing sand by spreading it over
the surface and brushing it into the joints. The dry sand shall be natural and shall comply with
the corresponding grading requirement given in Table 11.2. The block paving shall be
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vibrated to ensure that the joints have been completely filled.

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Table 11.2
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Grading for laying course & jointing sand

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% Passing
Sieve Size
Laying Course Sand Jointing Sand
10 mm 100
5 mm 90-100 100
2.36 mm 75-100 95-100
1.18 mm 55-90 90-100
600 m 35-70 55-100
300 m 8-35 15-50
150 m 0-10 0-15
75 m 0-3 0-3
11.5 PRECAST CONCRETE PAVING SLABS
1 Precast concrete paving slabs shall be hydraulically pressed, complying with BS EN 1339.
2 The dimensions of precast concrete paving slabs shall be as per Table 3 of BS EN 1339
unless shown otherwise on the contract drawings.
3 Where permitted by the Engineer as an alternative, slabs 450 mm x 450 mm and smaller
may be bedded on a layer of clean sharp sand complying with BS EN 12620 Grading C or M,
25 mm  10 mm thick.
4 On circular work where the radius is 12 m or less, all slabs shall be radially cut on both edges
to the required line.
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5 Transverse strength and water absorption requirements shall be assessed in accordance
with BS EN 1339 - appendix B and appendix C; respectively. The loads at failure shall not be
less than the appropriate value given in Table 11.3 and the water absorption shall not exceed
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the limit given in the aforementioned Table.
Table 11.3
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Transverse strength and water absorption of flags
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Minimum load at failure for thickness
Maximum water
(kN)
Flag type absorption in %
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by mass
50 mm 60 mm 63 mm 65 mm 70 mm
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A 8.3 - 12.7 - -
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B,C,D 11.1 - 16.9 - -

E 9.6 - - - 18.8 4.0
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F 9.1 - - 15.4 -
G 9.6 13.8 - - -
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6 The mortar bed shall be spread only after the base has been approved by the Engineer. The
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subbase shall be tested for density and the minimum density shall be greater than 95% of the
maximum dry density.
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7 Slabs shall be laid in accordance with BS 7533 to the designated cross-section and with
joints at right angles to the kerb.
8 Slabs shall be bedded on a sand/cement (3:1) mortar bedding not less than 10 mm and not
more than 40 mm thick.
9 Unless designated elsewhere paving slabs shall be laid with close joints of between 2 to 4
mm. After laying the joints shall be filled with sand complying with clause 8.3.3.
10 Where designated paving slabs shall be laid with open joints of between 5 to 10mm laid in
accordance with BS 7533.
11.6 CAST-IN-PLACE CONCRETE PAVED AREAS
1 Cast-in-place concrete for footways and paved areas shall only be permitted for small areas
where it is awkward or impractical to use one of the alternative paving materials specified in
this part of the specification.
2 The use of steel reinforcement bars or mesh in cast-in-place concrete slabs is not permitted.
3 Paving shall be cast in sizes to avoid the formation of shrinkage cracks. The actual maximum
size of area to be cast at one time will be advised by the Engineer based on the mix design
and layer thickness shown on the drawings. The Contractor may be permitted to cast larger
areas at one time if non-metallic fibres are added to the concrete mix to eliminate cracking. In
such cases the maximum pour size shall be proposed by the Contractor and approved by the
Engineer.
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4 Cast-in-place concrete for footways and paved areas shall be mixed, laid and cured as
described in Section 5.
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5 The grade of concrete, layout, thickness, position of joints and surface finish shall be as
designated.
6
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Cast-in-place concrete shall be laid on a designated sub-base in accordance with Part 4.
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11.7 BITUMINOUS PAVED AREAS
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1 Flexible surfacing for footways and paved areas shall be made and laid in compliance with
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Part 5.
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2 The type of mix and the surface treatment/finish to the paving will be as designated..
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3 Surfacing shall be laid to true levels and crossfalls and be of the designated thickness.
4 Surfacing shall be laid on a designated sub-base in accordance with Part 4.

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END OF PART
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Part 12: Fencing
12 FENCING ....................................................................................................... 2
12.1 GENERAL ...................................................................................................... 2

12.1.1 Scope 2
12.1.2 References 2
12.1.3 Submittals 3
12.2 FENCING GENERALLY ................................................................................ 3
12.3 CHAIN LINK FENCING.................................................................................. 4

12.3.1 General 4
12.3.2 Materials 4
12.3.3 Gates 5
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12.3.4 Finish to Components 6
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12.3.5 Construction 6
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12.4 STRAINED WIRE FENCING ......................................................................... 7
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12.4.1 General 7
12.4.2 Materials
12.4.3 Installation nt 8
10
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12.5 PEDESTRIAN GUARD-RAIL ....................................................................... 11
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12.5.1 Aluminium Guard Rails 11

12.5.2 Galvanised Steel Rails 12
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12.5.3 Materials and Fabrication 12

12.5.4 Installation 13
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Part 12: Fencing
12 FENCING
12.1 GENERAL
12.1.1 Scope
1 This part of the specification covers the materials and installation requirements for the
following permanent fence types. The definition of each type is given in the relevant section
of the specification.
(a) chainlink fencing.

(b) strained wire fencing.
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(c) pedestrian guard-rail.
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This Section
Part 1 General
Part 10 Vehicle Crash Barriers
Section 5, Concrete nt
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12.1.2 References
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BS 4............................Structural steel sections

BS 970........................Wrought steels for mechanical and allied engineering purposes
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BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
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BS 1490......................Aluminium and aluminium ingots for engineering purposes

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BS 1722-2 ..................Strained wire fences

BS 1722, Part 1 ..........Chain link fences
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BS 1722, Part 2 ..........Rectangular wire mesh and hexagonal wire netting fences
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BS 4102......................Specifications for steel wire and wire products for fences

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BS 4320......................Metal washers for general engineering purpose

BS 4464......................Spring washers for general engineering and automobile purposes
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BS 4652......................Specifications for zinc rich priming paint
BS EN 1011................Welding
BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
BS EN 10210-2 ..........Hot finished structural hollow sections of non alloy and fine grain steels
BS EN 10244-2 ..........Steel wire and wire products
ASTM A53 ..................Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated
Welded and Seamless
ASTM A193 ................Specification for Alloy-Steel and Stainless Steel Bolting Materials for
High-Temperature
Part 12: Fencing
ASTM A240 ................Specification for Heat-Resisting Chromium and Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels
ASTM B108 ................Specification for Aluminium-Alloy Permanent Mould Castings
ASTM B221 ................Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes,
and Tubes
ASTM D4364 ..............Practice for Performing Accelerated Outdoor Weathering of Plastics
Using Concentrated Natural Sunlight
ASTM Dl499 ...............Standard practice for filtered open-frame carbon-arc exposure of
plastic
ASTM G152................Standard practice for operating open flame carbon-arc light apparatus
for exposure of non-metallic materials
ASTM G153................Standard practice for operating endorsed arc light apparatus for
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exposure of non-metallic materials.
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ASTM G23..................Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type)
With and Without Water for Exposure of Non-metallic Materials
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AASHTO M181...........Chain link fence
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USA Federal Salt Spray Test (Test Standard 141 Method 6061)
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12.1.3 Submittals
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1 For all fencing systems, the Contractor shall submit the following for the Engineer’s approval,
before an order is placed with the manufacturer:
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(a) Name and address of the factories at which the required materials will be
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manufactured.
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(b) Technical submittals accompanied by a completed specification in the English

language, catalogues and a tabulation showing the overall dimensions of each type
and size of the required materials.
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(c) Programme of delivery certified by the manufacturer and supplier.

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(d) Detailed drawings.

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(e) Material composition certificates.

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(f) Technical information for the materials and system.
2 The submittals shall clearly show the standard to which the material complies. All materials
shall meet the requirements of the relevant BS. The Engineer may accept materials that
comply to a comparable international standard if the contractor demonstrates that the
standard is equivalent.
12.2 FENCING GENERALLY
1 All permanent fencing, unless otherwise designated shall be erected to present a flowing
alignment both in plan and elevation following approximately the level of the finished ground
along the line of the fence. The Contractor shall trim or fill the ground along the line of the
fence when required. The fencing shall be neatly and effectively joined to existing fences and
to other structures and parapets.
Part 12: Fencing
2 Where designated, existing fences, gates and stiles, with posts shall be carefully taken down,
laid aside, removed or later re-erected. Fences, gates, stiles and posts which are to be re-
erected shall be handled carefully to avoid any damage.
12.3 CHAIN LINK FENCING
12.3.1 General
1 This work consists of the supply and installation of all plastic coated chain link fencing
complete with all necessary hardware and appurtenances as designated and in conformity
with the lines and grades directed by the Engineer.
2 All materials to be furnished and installed shall conform to all requirements of BS1722: Part 2
except as otherwise designated.
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12.3.2 Materials
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1 The base metal for the manufacture of posts and braces shall conform to the requirements of
BS1722: Part 1, except that the carbon content of steel posts shall not be more than 0.4 % if
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welding is required. Posts and braces shall be galvanised in accordance with BS EN ISO
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1461.
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Fence posts and braces and gate frames shall be pipe conforming to the requirements of
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Table 12.1 unless otherwise designated:
Table 12.1
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Fence posts and braces and gate frames requirements

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Location Minimum O.D., mm Minimum Weight, kg/m

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End, Corner, Pull Posts 60.3 5.43

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Line Posts 48.3 4.05

Braces 42.2 3.38
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3 Posts for each side of gates shall be pipe conforming to the requirements of Table 12.2:
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Table 12.2
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Post dimensions for chain link fences
Gate Opening, m Minimum O.D., mm Minimum Weight, kg/m
1.5 60.3 5.43

4.0 73.0 8.62
4 All fence and gate posts (including all end and corner posts) shall be fitted with plastic or vinyl
coated aluminium tops designed to fit securely over the posts and crowned to shed water.
5 Changes in line where the angle of deflection is 15° or more shall be considered as corners
and corner posts shall be installed.
Part 12: Fencing
6 Extension arms, stretcher bars, and other required fittings and hardware shall be steel,
malleable iron or wrought iron and shall be hot dipped galvanised. All required fittings and
hardware shall be fastened to the posts in the proper manner.
7 Chain link fence fabric shall be galvanised steel fabric conforming to the BS1722: Part 1. The
base metal for the fabric shall be medium high carbon hot-dip galvanised steel wire. All chain
link fence fabric shall be woven into approximately 50 mm mesh such that in a vertical
dimension of 600 mm along the diagonals of the openings there shall be at least 7 meshes.
8 Between posts, chain link fabric shall be fastened to a top and bottom tension cable. The
tension cable shall be 10 gauge galvanised steel.
9 Tie wires and post clips shall be at least 9 gauge galvanised steel.
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10 Turnbuckles and truss tighteners shall be fabricated of steel, malleable iron, or wrought iron
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and shall be hot dipped galvanised. The truss tighteners shall have a strap thickness of not
less than 6 mm.
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11 The class of concrete for post footings shall be as designated.
12.3.3 Gates nt
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1 Gate frames shall be constructed of not less than 42.2 mm galvanised pipe weighing
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3.38 kg/m and conforming to ASTM A53. Gate frames shall be cross trussed with 9 mm
adjustable truss rods. The corners of gate frames shall be fastened together and reinforced
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with a malleable iron fitting designed for the purpose or by welding. All welds shall be ground
smooth.
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2 Chain link fence fabric designated for the fence shall be attached to the gate frame by the
use of stretcher bars and the tie wires as designated for fence construction, and suitable
tension connectors shall be spaced at approximately 300 mm intervals.
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3 The gates shall be hung by at least two steel or malleable iron hinges not less than 80 mm in
width, so designed as to securely clamp to the gate post and permit the gate to be swung
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back against the fence. The bottom hinge shall have a socket to take the bail end of the gate
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frame.
4 Gates shall be provided with a combination steel or malleable iron catch and locking
attachment of approved design. Stops to hold gates open and a centre rest with catch shall
be provided where required.
5 All gates shall be provided with standard hardware and heavy duty padlocks with four keys
each, the type and details of which shall be to the approval of the Engineer.
Part 12: Fencing
12.3.4 Finish to Components
1 All posts, gate frames, rails and similar materials shall have a coating thickness of 254 to 356
micron of a polyvinyl chloride (PVC) which has been chemically bonded to the metal surface
with an appropriately cured primer. Final finish colour shall be as designated.
2 Chain link fence fabric shall have a vinyl coating of minimum wall thickness of 0.559 mm over
the galvanised substrate. The vinyl coating shall be continuously extruded (not sprayed or
dipped) over the galvanised steel wire by the thermal extrusion process under pressures to
352 kg/cm2 to ensure a dense and impervious covering free of voids, having a smooth and
lustrous surface appearance.
3 The wire shall be vinyl-clad before weaving and shall be free and flexible at all joints.
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4 Colours shall be stabilised and have a light fastness that shall withstand a minimum
WEATHER-O-METER exposure time of 4000 h without any deterioration in accordance with
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ASTM Dl499 and G23, Type E. Alternatively a sample of fencing may be subject to an
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exposure time of 2000 h at 85 °C humidity in a humidity oven. The sample shall exhibit no
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colour loss, cracking, peeling, blistering or other deterioration.
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5 The vinyl-clad wire shall withstand an accelerated ageing test of 2000 hours at 62 °C without
cracking or peeling.
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6 The vinyl covering shall, in addition, resist attack from prolonged exposure to dilute solutions
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of most common mineral acids, sea water and dilute solutions of most salts and alkali.
7 The pipe resin formulation shall meet the standard ASTM D4364, minimum 5000 h
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WEATHER-O-METER requirement without cracking, blistering, or loss of adhesion. The

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protective resin coating shall withstand an impact resistance test (Gardner Test Method) of a
minimum of 1850 mm/kg. Certified abrasion resistance shall be in excess of a ten minute
blast of 5.6 kg/cm2 at 305 mm at 25 °C with S230 shot at an impingement angle of 90 °
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without exposing the steel substratum.

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8 It shall not support combustion and shall be self-extinguishing; and shall withstand a salt
spray test (Federal Test Standard 141, Method 6061 of greater than 10,000 h with no
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perceptive deterioration to coating or evidence of metal corrosion for unscored samples. For
scored samples after exposure of 1000 h, under-cutting shall not exceed 5 mm. The
protective resin coating shall exhibit a chemical resistance after prolonged exposure at 24 °C
to fumes.
12.3.5 Construction
1 Line posts shall be spaced at not more than 3.0 m intervals, measured from centre to centre
of posts, in general, in determining the post spacing, measurement will be made parallel to
the slope of the natural ground, and all posts shall be placed in a vertical position, except in
unusual locations where the posts shall be set perpendicular to the ground surface if so
directed by the Engineer.
2 All posts shall be set in concrete footings conforming to the designated details.
Part 12: Fencing
3 End, corner, pull and gate posts shall be braced to the nearest line post with galvanised
diagonal or horizontal braces used as compression members and galvanised 9 mm steel
truss rods with turnbuckles or truss tighteners used as tension members.
4 Pull posts shall be placed at locations agreed by the Engineer. They shall be placed at 200 m
intervals between posts to which the ends of the fabric are clamped or midway between such
posts when the distance is greater than 40 m but less than 200 m.
5 Chain link fabric shall be fastened on the side of the posts designated by the Engineer.
6 The fabric shall be stretched and securely fastened to the posts, and between posts the top
and bottom edges of the fabric shall be fastened to the tension wires. Tension wires shall be
stretched tight, the bottom tension wire shall be installed on a straight grade between posts
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by excavating at the high points of ground and in no case will filling of depressions be
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permitted.
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7 The fabric shall be fastened to end, corner and gate posts tall with minimum 10 mm diameter
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steel stretcher bars and not less our than 3 mm by 18 mm stretcher bar bands spaced at
maximum or 300 mm intervals. The fabric shall be fastened to line posts ends and tension
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wires with tie wires or post clips. The fasteners shall be spaced at maximum intervals of 500
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mm.
12.4 STRAINED WIRE FENCING

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12.4.1 General
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1 Strained wire general and dropper fences shall be as designated and they shall comply with
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BS 1722-2 with the following amendments.

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2 This part of the specification covers the requirements for materials and workmanship for
strained wire fences of the general pattern and of the dropper pattern. Droppers are defined
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as intermediate and vertical stiffeners between some or all of the wires that are used to
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maintain the spacing of the wires. The droppers are not connected to the ground.
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3 Strained wire fences comprise of tensioned horizontal steel wires fixed between vertical
straining posts with support angle struts and connected to intermediate posts. Posts shall be
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constructed of either steel or precast reinforced concrete and anchored in concrete

foundations.
4 Wire dropper fencing shall be provided at locations where it is necessary to restrict the
access of vehicles, and camels and wandering animals.
5 Strained wire general and dropper fences shall be of one of the types shown in Table 12.3
6 The strained wire fences shall be coded according to the type dependant on the number of
line wires, whether droppers are used, material used for the posts, these type references are
given in Table 12.3. The first letter indicates that it is either a general pattern or a dropper
pattern strained wire fence, the second letter indicates the type of posts that are used, the
numbers give an indication of the height of the fence e.g. DC90 indicates a 0.9m high fence
with concrete posts and droppers.
Part 12: Fencing
7 For the sake of uniformity quoted heights of those to the top wire and exclude any variation in
ground clearance to the base, the third letter where present indicates the number of line
wires.
Table 12.3
General Characteristics of Strained Fences - Fence Types
With Concrete Height of
With Steel Posts With Wooden Posts Spacing between
Posts Top Wire &
horizontal wires,
General Dropper General Dropper General Dropper Number of
from the top wires
Pattern Pattern Pattern Pattern pattern Pattern Wires
m No. mm
DC 90 SS90 DS90 SW90 DW90 0.90 3 330,330
SC105A DC105A SS105A DS105A SW105A DW105A 1.05 5 250,250,230,150
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250,250,230,150,
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SC105B SS105B SS105B DS105B SW105B DW105B 1.05 6
100
250,250,230,150,
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SC120 DC120 SS120 DS120 SW120 DW120 1.20 6
150
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250,250,230,150,
SC135A DC135A SS135A DS135A SW135A DW135A 1.35 7
150,150
SC135B DC135B SS135B DS135B SW135B nt

DW135B 1.35 8
250,250,230,150,
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150,150,100
DW135 250,225,225,150,
SC135C DC135C SS135C DS135C SW135C 1.35 9
C 125,125,100,75
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225,225,200,175,
DC180 DS180 DW180 1.80 11 175,175,150,150,
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125,100
100,100,100,100,
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DC210 DS210 DW210 2.10 16

100
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12.4.2 Materials
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1 The sizes stated for components are the minimum requirements and it is permissible to use
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larger sizes except where this would adversely affect the fit of the components or where
replacement parts need to match those already present.
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2 Line wire shall comply with BS 4102 and shall be one of the following:
3 Zinc coated low carbon steel with a nominal wire diameter of either 4.5 or 5mm
4 Zinc coated high tensile wire with a nominal wire diameter of 3.15mm
5 Plastic coated high tensile wire having a tensile strength of 1050 N/mm2 with a Zinc coated
core of 3.15mm nominal core diameter and a 4 .0mm overall diameter.
6 Stirrup wire shall comply with BS4102 and shall be of zinc coated low carbon steel with grade
A plastic coated low carbon steel and should have a nominal wire core diameter of 2.5 mm.
7 Barbed wire shall comply with BS 4102, shall be zinc coated and made from either low
carbon steel or high tensile steel wire.
Part 12: Fencing
8 The materials, protective treatment, tolerances on size and general construction details of
steel posts and struts, for strained wire fences shall comply with the requirements for chain
link fences, except that components shall not be plastic coated unless specifically required
under the contract documentation.
9 The materials and tolerances on precasting of all concrete components shall comply with the
relevant parts of section 5.
10 The minimum concrete grade for posts shall be C25 and the minimum cement content
should be 350 kg.
11 The mixing, placing and compaction of the concrete shall be as per Section 5.
12 All inserts and holes cast into precast concrete components with posts shall be adequate for
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the bolts or appurtenances to be fitted.
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13 All holes shall be free from obstructions and accurately positioned.
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14 The minimum grade of concrete to be used for posts shall be C25 and the minimum cover to
embedded steel in posts shall be 50mm.
15 nt
The dimensions of concrete fence posts and struts shall be as given in Table 12.4.
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16 Posts shall be reinforced with 4 steel reinforcing bars of the size given in Table 12.4.
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17 Straining posts and struts shall not be tapered.

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18 The dimensions and details of the foundations shall be as shown in the contract drawings.
Concrete for foundations for the bases of posts and struts shall comply with the requirement
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of section 5 of the specification and shall be grade C15.

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19 Straining posts shall be provided with a firm bearing struts at a point within the top of the
length of the string posts, measured above the ground level.
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20 Straining posts shall be provided with holes for the attachment of straining fittings.
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21 Where line wires are to be passed through them, struts shall be provided with either holes or
slots.
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22 Intermediate posts shall be tapered to 75mm x 75mm at the top and shall be holed to allow
the attachment of line wires.
23 High bolt strain shall consist of bolts of 250mm overall length, not less than 9.5mm diameter
with an eye at one end. They should be threaded and fitted with nuts and washers.
24 2 way eye bolt strainers shall be fitted with ring nuts. They shall be hopped and galvanised to
BS EN ISO 1461. Widening brackets intended for attachment to the post shall be
manufactured from mild steel flat not less than 25mm x 3mm and shall be fitted with a
widening bolt 12mm minimum diameter with a friction type ferrule or ratchet winder.
25 Hair pin staples shall be of not less than 3mm diameter round wire or sectional wire of the
same cross sectional area and shall have a zinc coating complying with BS EN 10244-2.
Part 12: Fencing
26 Droppers shall be at least 65 mm longer than the distance between the top and bottom wires
covered by them and shall be made of steel of the section not less than 0.0066 kg/m or steel
wire or galvanised in accordance with BS EN ISO 1461.
Table 12.4
Concrete Fence Posts and Struts
Intermediate Posts Strain Posts Struts

Height
Reinf. Reinf. Reinf.
Length Section Length Section Length Section
Dia. Dia. Dia.
mm x mm x mm x
m m mm m mm m mm
mm mm mm
100 x 100 5 75 x 75
0.90 1.57 100 x 100 1.57 or or 1.50 or 6
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125 x 125 8 100 x 75
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100 x 100 5 75 x 75
1.05 1.72 100 x 100 1.87 or or 1.83 or 6
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125 x 125 8 100 x 75
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1.20 1.87 125 x 125 2.02 125 x 125 8 1.98 100 x 75 6
1.35a
and b
2.02 125 x 125 2.17
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125 x 125 8 2.13 100 x 75 6
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1.35c 2.17 125 x 125 2.32 150 x 150 10 2.13 100 x 75 6
1.80 2.62 125 x 125 2.77 200 x 200 12 2.73 100 x 100 8
2.10 2.92 125 x 125 3.07 200 x 200 12 3.03 100 x 100 8
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12.4.3 Installation
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1 Droppers shall be securely fixed to all the line wires covered by them and be of sufficient
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strength to maintain the spacing of the line wires and spread the load between them in use.
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2 The post shall be adequately braced in both directions after insertion into the wet concrete
and support shall be maintained till the concrete is fully hardened.
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3 Excavation for foundations for post and struts shall be of the minimum stipulated dimensions
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at the base of the hole.

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4 When erecting fence posts the concrete shall be placed in position before the
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commencement of the initial set.
5 The entire foundation hole shall be filled with concrete, the use of partly backfilled holes shall
not be permitted. Straining posts shall be provided at the ends and corners of changes of
direction or acute variations in level and at intervals not exceeding 150m for mild steel line
wire or 300m for high tensile line wire in straight lengths of fence.
6 Struts shall be provided at each straining post.
7 Where there is a change in plan direction of the fence two struts shall be provided.
8 Intermediate posts shall be provided at intervals measured centre to centre of posts not
exceeding 3.5m.
9 The number of line wires shall be as given in Table 12.3.

Part 12: Fencing
10 The top wire shall be secured with approximately 75mm below the top of the posts, each line
wire shall be strained tightly and secured to each straining posts by either widening brackets
attached to the post with fixing bolts or high bolt strainers passing through a hole in the post
and secure with a nut and washer.
11 If barbed wire is specified it shall be attached to the straining posts and intermediate posts by
the same method as the line wire.
12 Attachment to intermediate posts with the exception of the high tensile line wire for which
stirrups are not permitted each line wire shall be secured to each intermediate posts by one
of the following means;
13 A wire stirrup pass through a hole in the posts secured to the
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14 a hairpin stapled post through a hole in the post and the ends twice bent over
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15 A line wire pass through a hole in the post
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16 Small areas of hot dipped galvanised coating damaged by welding cutting or by excessively
rough treatment during the transit and erection shall be renovated either by the use of melting
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point zinc alloy repair rods or powders made specifically for this purpose or by the use of at
least 3 coats of good quality zinc paint as per BS 4652. Sufficient material shall be applied to
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provide a zinc coating at least equal in thickness.
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17 Droppers shall be attached after all wires have been strained and secured in position.
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18 The interval between dropper and the posts or between adjacent droppers shall not exceed
the following:
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(a) For full length droppers 2m.

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(b) For sectional droppers, bottom wires 2m.

(c) Top wires 2.5m.
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19 Where sectional droppers are used the ends of all droppers or adjacent levels of wire shall
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be fixed to at least one wire common to both levels.

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20 When measured within 14 days of erection the settled tension in the line wire between
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straining posts at 100 m apart shall be at least 1.6 kN
21 The method of approximately measuring the tension shall be as described in appendix F to

BS 1722-2.
12.5 PEDESTRIAN GUARD-RAIL
12.5.1 Aluminium Guard Rails
1 This Sub-section covers the requirements for the supply and installation of aluminium
pedestrian guard-rails and accessories.
2 Guard-rails shall be constructed to the designated line and grade and shall not reflect any
unevenness in the founding construction. Unless otherwise designated, railing posts shall be
vertical. For bridges, railing shall not be placed on a span until centring or falsework has been
removed, rendering the span self-supporting.
Part 12: Fencing
3 The foundation details for the fence shall be as per the designated details and dimensions.
12.5.2 Galvanised Steel Rails
1 Galvanised steel pedestrian guard rails shall comply with the strength requirements of BS
3049 Clause ‘A’ and shall be fabricated to the dimensions shown on the drawings from hot
rolled steel section and bars to BS EN 10210-2 and BS 4360, Grade 43C.
2 The following Minimum steel section thickness shall be used:

Rails - Sealed hollow section : 2.5 mm
Other sections : 4.0 mm
Posts - Sealed hollow sections : 3.0 mm

Other sections : 5.0 mm
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3 Joints shall be welded by metal arc welding to BS EN 1011 except where shown otherwise on
the drawings.
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4 The guard rails and components shall be fabricated such that no burrs or sharp edges occur,
that the finished work is free from distortion and cracks and that welded joints are fully
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bonded, form accurate fit and are finished smooth and flush with adjacent surfaces.
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5 The guard rail components shall be fixed to the posts at the lower joints by 12 mm diameter,
80 mm long galvanised steel bolts with one galvanised steel washer through 40 x 40 x 6 mm
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cleats. End units shall be purpose made to project over the posts with a rounded end.
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6 Posts shall be closed at the top with a 6 mm plate having two 12.5 mm, 25 mm long dowels
welded thereto. The holding down plate at the bottom of the post shall be a minimum of 20 x
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100 x 6 mm thick.
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7 All steel posts shall be hot dip galvanized both inside and outside to BS EN ISO 1461. “-end
of specification addition.
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12.5.3 Materials and Fabrication

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1 Material for cast aluminium guard-rail posts shall conform to the requirements of AASHTO
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M193 and ASTM B108, alloy S7A - T4 (A444 - T4).

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2 Aluminium alloy extruded rail shall conform to the requirements of ASTM B221 alloy, 6061-T6
or 6351-T5 with a minimum yield strength of 2466 kg/cm2, a minimum tensile strength of
2677 kg/cm2 and an elongation of 10 % in 50 mm.
3 Stainless steel hardware for aluminium railings shall be machine bolts or cap screws
conforming to ASTM A193, grade B8, Class 2.
4 Stainless steel flat washers and lock washers shall conform to the requirements of ASTM
A240, Type 302.
Part 12: Fencing
5 Material 12.7 mm thick or less may be cut by shearing, sawing or milling. Material over 12.7
mm thick shall be sawed or milled. Cut edges shall be true and smooth and free from
excessive burrs or ragged breaks. Re-entrant cuts shall be filleted by drilling before cutting.
Flame cutting will not be permitted. Material may be heated to a temperature not exceeding
240 °C for a period not exceeding 30 minutes to facilitate bending unless cold bending is
required to retain the original mechanical properties of the material furnished.
6 Rivet and bolt holes shall be drilled to finished size or stub punched smaller than the nominal
diameter of the fastener and reamed to size. The amount by which the diameter of a stub
punched hole is smaller than that of the finished hole shall be at least one-quarter the
thickness of the piece. The finished diameter of circular holes shall be not more than 7 %
greater than the nominal diameter of the fastener. Slotted bolt holes to take care of
expansion shall be provided as designated. Anchor-bolt holes may be up to 25 % greater
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than the nominal bolt diameter with a maximum of 12.7 mm greater than the nominal bolt
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diameter.
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12.5.4 Installation
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1 The Contractor shall co-ordinate and space the rail posts to miss any items which may be
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furnished and installed under this Contract. The Contractor shall also co-ordinate and space
the rail posts to miss lighting poles and any other existing obstructions.
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2 Where aluminium alloys come in contact with other metals, except stainless steel, the
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contacting surfaces shall be thoroughly coated with an aluminium-impregnated caulking

compound, or a synthetic rubber gasket may be placed between the two surfaces. Aluminium
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alloys shall not be placed between the two surfaces. Aluminium alloys shall not be placed in
contact with copper, copper base alloys, lead or nickel.
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END OF PART
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Part 13: Traffic Signs, Markings and Studs
13 TRAFFIC SIGNS, MARKINGS AND STUDS ................................................. 2
13.1 GENERAL ...................................................................................................... 2

13.1.1 Scope 2
13.1.2 References 2
13.1.3 Definitions for Reflective Traffic Studs 2
13.1.4 Submittals 3
13.2 TRAFFIC SIGNS ........................................................................................... 3
13.2.2 Sign Foundations 4
13.2.3 Traffic Sign Materials 5
13.2.4 Installation Requirements for Traffic Signs 7
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13.2.5 Advance and far Advance Directional Signs 8
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13.3 PAVEMENT MARKINGS ............................................................................. 10
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13.3.2 Materials for Pavement Markings 10
13.3.3
13.3.4
Application of Thermoplastic
Performance Requirements and Testing nt 12
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13.3.5 Protection of Pavement Markings 14
13.4 TEMPORARY ROAD MARKING ................................................................. 14
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13.4.1 ROAD MARKING PAINT 14

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13.4.2 ADHESIVE ROAD MARKING STRIP 15

13.4.3 REMOVAL OF ROAD MARKINGS 15
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13.5 REFLECTIVE STUDS ................................................................................. 15

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13.5.1 General 15
13.5.2 Reflectors 16
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13.5.3 Reflectivity 17
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13.5.4 Installation of Reflective Studs 18

13.6 NON-REFLECTIVE STUDS ........................................................................ 19
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13.6.1 General 19
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13.6.2 Materials and Manufacture 20

13 TRAFFIC SIGNS, MARKINGS AND STUDS
13.1 GENERAL
13.1.1 Scope
1 This Part covers the supply and installation of traffic signs (complete with posts and
foundations), thermoplastic road marking, road marking paint for temporary roads and
diversions, reflectorised studs and non-reflective studs.

This Section
Part 16, Traffic Signals
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Section 5, Concrete
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13.1.2 References
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1 The following manuals and standards are referred to in this Part:
Qatar Traffic Control Manual nt
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BS 381C .....................Colours for identification purposes
BS 873........................Road traffic signs
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BS 1470......................Wrought aluminium for general engineering purposes; plate sheet and

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strip
BS 1474......................Wrought aluminium for general engineering purposes; bar, extruded
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round tubes and sections

BS 1490......................Aluminium and aluminium alloy ingots for general casting purposes
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BS 2000, Part 58 ........Determination of softening point of bitumen (ring and ball)

BS 3262,(Part 1) l989 .Hot applied thermoplastic road marking materials
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BS 6088 1981.............Solid glass beads for Road Marking

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BS EN ISO 591-1 .......Titanium dioxide pigments

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BS EN ISO 1461 ........Hot dipped galvanising

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ASTM A307 ................Steel anchor bolts

ASTM C373 ................Standard test methods for water absorption
ASTM C424 ................Test methods for crazing resistance
CML 14-97..................Standard Method of test for determination of appearance, shape,

dimensions
and compressive strength of ceramic non-reflecting road studs.
TRL Road Note 27 .....Skid resistance portable tester.
13.1.3 Definitions for Reflective Traffic Studs
1 Entrance Angle: The angle in the horizontal plane between the direction of incident light and
the normal (perpendicular) to the leading edge of the stud.
2 Observation Angle: The angle at the reflector between observer's line of sight and the
direction of the light incident on the reflector.
3 Specific Intensity (S.I.): The candle-power of the returned light at the chosen observation and
entrance angles for each foot candle of illumination at the reflector on a plan perpendicular to
the incident light.
13.1.4 Submittals
1 Within three weeks of acceptance of the manufacturer's tender, the Contractor shall submit
for approval working drawings for signs posts and base plates. Fabrication shall not begin
until approval has been given.
2 The Contractor shall submit detailed drawings of the foundations proposed for traffic signs.
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3 The Contractor shall submit samples of the proposed materials for approval on request by
the Engineer before delivery to Site, at his own cost.
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4 The Contractor shall submit to the Engineer for approval three copies of his working drawings
for all traffic sign faces both in Arabic and English. Size and style of lettering shall be as
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designated. No order shall be placed without written agreement of the Engineer and the
Concerned Authorities.
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5 Before proceeding with drilling holes for sign foundations, the Contractor shall submit to the
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Engineer for approval; the type of plant proposed for drilling holes, details of any temporary
metal casings, proposed method of concreting and the proposed method of conduit
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installation.
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13.2 TRAFFIC SIGNS

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13.2.1 Scope of Work
1 This work shall consist of furnishing and installing road signs and posts assemblies as
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designated. All sign faces and lettering shall be in accordance with the Qatar Traffic Control
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Manual. The required post sizes for different sign sizes shall be as tabulated in the Qatar
Traffic Control Manual. Where in this section of the specification the term “designated” is
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used, this refers to the contract drawings and the Qatar Traffic Control Manual.
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2 The minimum depths and sizes for sign foundations shall be as per the requirements of the
Qatar Traffic Control Manual. For each of the signs the Contractor shall submit design
calculations for the proposed foundations.
3 The following documents should be specifically referred to for this work;
(a) BS 873
(b) Qatar Traffic Control Manual
4 Permanent traffic signs shall be reflectorised or non reflectorised illuminated and shall, in
respect of quality, comply with the requirements of the latest editions of;
(a) BS 873
(b) Qatar Traffic Control Manual
5 In the case of conflict with these specifications and the above documents, the matter shall be
referred to the Engineer.
6 All foundations, framing and fixings for information signs shall be suitable for local conditions.
The design calculations shall be submitted to the Engineer for approval. The wind loads shall
be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.
7 A positive system of identification of signs, posts and all fittings shall be adopted. The
reference number of the sign together with the date of manufacture shall be indicated by self-
adhesive numbers on the reverse side of the sign in the bottom left hand corner and in a
consistent and readily visible position on all posts and fittings. The manufacturer's name of
trademark will not be permitted on the face of the sign. It may be affixed on the back of the
sign, provided approval to the size and colour of the mark has been obtained from the
Engineer. Any previously marked reference number should be transferred to new signs on
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replacement.
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8 All road signs shall be guaranteed by the Contractor against any defect in material and
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workmanship for a period of five years from the date of completion of the Works under the
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Contract. If any defect should arise due to poor material or workmanship, it shall be rectified
by the Contractor.
13.2.2 Sign Foundations

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1 Sign foundations shall either be reinforced concrete columns in drilled holes or shallow
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reinforced concrete spread footings. The dimensions and details of the foundations shall be
as designated.
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2 The number of anchor bolts and bolt locations and anchor bolt dimensions shall be as
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designated. All anchor bolts nuts and washers shall be hot dipped galvanised to BS EN ISO
1461. Any protruding parts to the bolt thread or nut shall be further protected by the
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application of a wax or grease impregnated tape. Any conduit cast into the foundation for
cable access shall be mild steel, hot dipped galvanised after fabrication to BS EN ISO 1461.
The minimum bend of conduit shall be 600 mm radius.
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3 All concrete and reinforcing steel used in the sign foundations shall be of the designated
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grade and type and shall comply with the requirements of Section 5. Anchor bolts shall
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comply with the requirements of ASTM A307 with a minimum tensile strength of 414 N/mm .
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4 Each bolt shall be supplied with two hexagonal nuts for levelling purposes complete with
washers.
5 If an obstruction is encountered whilst drilling the foundation hole the Contractor shall inform
the Engineer. The Contractor may elect to bore or drill through the obstruction depending on
its nature or may propose to reallocate the signs slightly to avoid the obstruction subject to
the approval of the Engineer. In either case the work is deemed to be included in the scope
covered by this Part.
6 The sides of excavation shall be vertical and any additional excavations carried out beyond
that designated, for the particular post and sign being erected, shall be filled with concrete or
granular material as directed by the Engineer.
7 The reinforcement cage shall be securely fixed centrally about the axis of the foundation, any
electrical conduit shall be securely fixed in position as designated before replacement of
concrete.
8 The top of the concrete foundation shall be finished with a steel trowel to a smooth finish.
9 The top of the concrete foundation shall not extend more than 100 mm nor less than 50 mm
above the finish grade level unless otherwise designated.
10 All backfilling and compaction shall be completed before the erection of any sign on the
structure.
11 All excavations shall be approved by the Engineer before the sign is erected and before
backfilling with fill or concrete as designated.
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13.2.3 Traffic Sign Materials
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1 Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC - 1/2H, NS3-
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3/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11 swg) or from extruded
aluminium plank sections to BS 1470, HE 9-WP, HE 9P or HE 30-WP or extruded aluminium
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alloy plank sections to BS 1474, HE 9 TE and HE 30 TF. However information signs shall be
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constructed in extruded aluminium planks, which will either be self-locking or rear fixing, and
the aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent
International standard.
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2 All sign plates shall have clean, smooth edges cut to the required shape of the sign, and shall
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be etched and degreased to the sign sheeting manufacturer's specifications before

application of the sheeting.
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3 Illuminated signs shall be covered with "Super Engineering Grade" reflective sheeting.
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4 Reflective signs shall be covered over the whole front face with "High Intensity" reflective
sheeting. The sheeting shall be of the designated colour and shall have a manufacturer's
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guarantee of not less than five years. The rear faces shall be non-reflective grey and should
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give a similar life span to the sign face.

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5 The reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive
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using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in
accordance with the sheeting manufacturer's instructions.
6 Sign faces shall be formed from a single piece of reflective sheeting, but if for any reason the
sign face must be fabricated from more than one piece of material all joints in the material
shall be overlapped by not less than 6 mm and where sheeting is applied to extruded
sections it shall extend over the top and bottom edges of the sections by not less than 3 mm.
No butt joints shall be permitted and in horizontal joints the overlap shall be from the top.
7 The corners of all direction signs shall be rounded to a radius of 75 mm.
8 Signs constructed of aluminium sheet shall, when recommended by the Traffic Signs Manual,
be framed on all edges using hot dipped galvanised steel angle or angle-channel of
equivalent section.
9 Signs constructed from extruded aluminium plank sections are to present the same flanged
appearance on all edges of the sign by fitting an aluminium end capping to the exposed ends
of the plank section on both sides of the sign.
10 Where the designated sign width requires the use of more than one length of plank section,
support beams shall be provided and positioned as approved by the Engineer.
11 For plank type signs supported on two posts the plank rails and support beams shall be
manufactured from one length of extruded aluminium section. One tie bar shall be fitted
between the bottom two plank rails (or the plank rail and support beam) at the centre of the
span between the mounting posts.
12 Where plank type signs are supported on more than two posts, and the designated sign
width is wider than the plank rail and support beams, the plank rail and support beam may
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comprise two or three lengths provided butt joints occur at an inner post. One tie bar shall be
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fitted between the bottom plank rail and support beam at the centre of the span between the
mounting posts.
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13 All stiffening and framing shall be continuous and shall prevent the sign from twisting.
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All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or
other material approved by the Engineer and shall have a sufficient cross-sectional area to
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prevent failure from thermal stresses or wind pressure or such other stresses as may be
designated.
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15 All rivet and bolt holes shall be edge-sealed with clear lacquer after the application of the
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plastics sheeting.
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16 Rivets shall be spaced at not more than l50 mm apart, around the outside edge of the sign
plate and on cross braces the spacing shall be not more than 300 mm.
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17 Any rivet brought through the sign face shall be coloured to match the sign face. Any rivet or
other device fixing sign plates to their frame work shall have a protective washer of nylon or
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other approved insulating material inserted where they would be in contact.

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18 All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates to support
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posts shall be manufactured from stainless steel. For plank type signs, brackets and clips
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shall be extruded aluminium alloy section.
19 Saddles shall be aluminium alloy or other material approved by the Engineer and shall be
provided with a nylon strip or other approved insulating material.
20 There shall be full adhesion of all sheeting material including letters, symbols and borders
and there shall be no air bubbles, creases or other blemishes.
21 All panels, cut-out letters, numbers, borders, symbols and back grounds on reflective
sheeting shall be carefully matched for colour at the time of sign fabrication to provide
uniform appearance both by day and night. The sheeting manufacturer's recommendations
on colour matching methods shall be observed. Non-uniform shading or undesirable contrast
between reflective sheeting on any one sign will not be accepted.
22 The edges of all applied sheeting materials including edges of all plates which make up a
sign, letters, symbols and borders shall be sealed as designated by the manufacturer.
23 Where required by the sheeting manufacturer the face of the sign plate shall have a coat of
clear lacquer of a type designated by him.
24 The top of sign support posts shall be capped with a plastic cap.
13.2.4 Installation Requirements for Traffic Signs
1 All sign faces shall be of the designated type, colour and size.
2 Signs delivered for use in the project shall be in new and unused condition, except where
otherwise designated; and shall be stored off the ground and under cover in a manner
approved by the Engineer. Any sign damaged, discoloured or defaced during transportation,
storage or erection shall be rejected.
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3 The position and mounting height of each sign shall be as designated.
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4 Designated post lengths are approximate only. When progress of the work is at the
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appropriate stage the Engineer will authorise the location of each sign, with the chainage and
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offset distance from the edge of the road pavement. The Contractor shall be responsible for
determination of the exact post lengths to provide the designated vertical clearance. Field
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cutting of posts shall be performed by sawing. Welded posts will not be permitted.
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5 All posts shall be erected vertically and where two or more posts are provided for any sign
the faces of these posts shall be lined up and their deflection angle checked for compliance
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with this Part before concreting in.

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6 For a period of 14 days after concreting in position, all posts shall be suitably braced to
prevent movement. Sign faces should not be fixed to posts until after the bracing has been
removed and the Engineer has inspected and approved the post stability and foundations.
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7 All posts shall be of the designated type and shall be protected against corrosion by hot dip
galvanising to BS EN ISO 1461.
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8 Unless otherwise designated, all signs shall be erected so that the edge and face of the sign
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are truly vertical and the face is at an angle of 95  to the centreline; that is, facing slightly
away from the centreline of the lane which the sign serves. Where lanes divide or are on
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sharp curves, the Contractor shall refer the orientation of the sign face to the Engineer for his
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instruction.
9 All sign supports shall be plumbed vertical.
10 The distance between the lower edge of the signs and the road surface shall be as
designated.
11 Signs shall be fastened to sign supports in accordance with the designated requirements and
the recommendations of the sign manufacturer to the satisfaction of the Engineer.
12 The Contractor shall at his own expense, immediately after erection and approval by the
Engineer cover the sign in order to prevent misleading information being displayed. The
covering shall be close weave hessian securely fixed over the face of the sign using a lacing
of nylon cord so as not to damage the sign. The Contractor shall maintain such coverings in
good order until receipt of the Engineer's instruction for their removal.
13 Signs shall be thoroughly cleaned immediately before being handed over. The type of
detergent used shall be approved by the Engineer.
13.2.5 Advance and far Advance Directional Signs
1 The face of the sign shall be completely covered with 3M Diamond Grade or similar approved
reflective material complying with the following Table 13.1A for retro-reflectivity.
Table 13.1A
Minimum Coefficients of Retro-Reflection
2
(a) 4° Entrance Angle
1
Observation Angle
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0.2° 0.33° 0.5° 1.0°
White 430 300 250 80
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Yellow 350 250 200 65
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Red 110 75 60 20
Green
Blue
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20
33
15
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10
10
4.0
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2
(b) 30° Entrance Angle
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Observation Angle
0.2° 0.33° 0.5° 1.0°

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White 235 150 170 50

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Yellow 190 130 140 40

Red 60 30 40 13
Green 24 18 19 5
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Blue 11 7 7 2.5
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2
(c) 90° Orientation, 40° Entrance Angle
1
Observation Angle
0.2° 0.33° 0.5° 1.0°

White 150 85 35 20
Yellow 125 75 30 17
Red 40 25 10 6
Green 15 8 3.5 2.0
Blue 6 4 1.5 0.7
1
Observation (Divergence) Angle – the angle between the illumination axis and the
observation axis
2
Entrance (Incidence) Angle – The angle from the illumination axis to the retroreflector axis
the retroreflector axis is perpendicular to the retroreflective surface.
3
Values for screened red colour on white sheeting may be significantly lower.
2 The material also shall satisfy the requirements of the following Tables 13.1B & 13.1C with
regard to colourimetric and photometric performance.
Table 13.1B
Chromacity factors
1 2 3 4 Limit Y (%)
Colour X Y X Y X Y X Y Min Max
White .035 .305 .355 .355 .335 .375 .285 .325 40 -
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Yellow .487 .423 .545 .454 .465 .534 .427 .483 24 45
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Red .690 .310 .595 .315 .569 .341 .655 .345 3 15
Green .030 .398 .166 .364 .286 .446 .201 .794 3 9
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Blue .078 .171 .150 .220 .210 .160 .137 .038 1 10
Table 13.1C
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Minimum Luminance Factors
Colour Factor
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Red 0.03
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Yellow 0.24
Blue 0.01
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White 0.40
Green 0.01
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3 All plastic sheeting shall be fixed in accordance with the sheeting manufacturer’s instructions.
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4 Unless otherwise agreed by the Engineer, sign faces shall be formed from a single piece of
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plastic sheeting.
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5 Where, with the agreement of the Engineer, more than one sheet is used the number of
sheets shall be kept to a minimum.
6 Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be
overlapped by not less than 6 mm. The overlap on the horizontal joints shall be from the top;
but joints in plastics sheeting shall not be permitted. The number of joints shall be kept to
minimum.
7 Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top
and bottom edges of these sections by not less than 3mm.
8 All materials comprising the sign face, including the background, border and legends shall be
carefully matched for colour at the time of sign fabrication to provide uniform appearance
both by day and night. The sheeting manufacturer’s recommendations on colour matching
methods shall be observed.
9 Letter, numerals, symbols and borders shall be of material compatible with the sheeting to
which they are applied. They shall be applied in accordance with the sheeting
manufacturer’s instructions.
10 Sheeting materials including letters, numerals, symbols and borders shall be fully adhered
with a pre-coated heat activated adhesive using a vacuum applicator equipped with a
temperature controller and there shall be no air bubbles, creases, cracks or other blemishes.
Application of the material shall be made using equipment specifically designed and
manufactured for the purpose by the sheeting manufacturer and maintained according to his
instructions. Where the sheeting manufacturer requires the assembly materials to be
provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be
applied at the time of fabrication of the sign face and shall be of a type specified or supplied
by the sheeting manufacturer.
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11 Details of the graphic designs, Arabic and English legends to be used on directional and
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certain informatory signs are given on the Contract Drawings. The Contractor shall submit
design drawings detailing the proposed layout of all such signs for the approval of the
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Engineer prior to their manufacturer. Otherwise, the signs shall be in accordance with the
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specified regulatory, warning and informatory signs detailed in the Qatar Traffic Manual,
Volume 1.
13.3 PAVEMENT MARKINGS

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13.3.1 Scope of Work
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1 This Work shall consist of the supply and application of thermoplastic road marking paint for
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marking of the pavement as outlined herein. It shall include the marking of the centreline, the
shoulder strip or edge, the barrier lines, the cross walks and any other markings required on
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the pavement for the control and direction of the traffic.

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2 Where designated, thermoplastic road marking paint shall be used in the construction of
rumble strips and jiggle bars. In such cases the requirements of this Part will apply except
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that the thickness and profile of the thermoplastic will be as per the designated details.
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3 The pavement markings shall be painted on the road to the dimensions and in the locations
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designated on the drawings as per Qatar Traffic Control Manual.

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4 The Contractor shall set out the markings and obtain the Engineer's approval before
beginning the work.
13.3.2 Materials for Pavement Markings
1 The material used shall conform to the superimposed type British Standard Specification for
Road Marking Materials BS 3262: Part 1. Where the materials do not conform to the BS
the deviations shall be clearly given in reference to the relevant tables and paragraphs of BS
3262: Part 1.
2 Ballotini shall comply with the requirements of BS 6088.
3 The material shall consist of light coloured aggregate, pigment and extender, bound together
with hard wearing resins, plasticised with oil as necessary in approximately the proportions by
weight as Table 13.1.
Table 13.1
Composition of Thermoplastic
Material Composition
Aggregate 40 %
Ballotini 10 - 20 %
Pigment and Extender 20%
Binder 20 %
4 The Contractor shall be responsible for blending the material to ensure that the performance
requirements of this part of the specification are met. This approximate composition of the
material as indicated above shall include the sprayed on ballotini.
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5 The grading of various ingredients shall be such that the final product, when in a molten
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state, can be sprayed on the surface at a nominal 1.5 mm thickness.
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6 The aggregate shall consist of white silica sand, crushed calcite, calcined flint or quartz, or
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other approved aggregate, and the colour shall comply, with the requirements laid down in
paragraph 4b of BS 3262: Part 1.
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7 Ballotini incorporated in the mixture shall be reasonably spherical, and free from flaws and
not less than 80 % shall be transparent glass. The grading of the ballotini shall be as stated in
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BS 6088.
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8 The pigment shall be titanium dioxide in accordance with paragraph 6a (I) of BS 3262: Part 1
and shall be not less than l0 % by weight of the mix.
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9 The extender shall be whiting in accordance with paragraph 6b of Part 1 of BS 3262.

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10 For yellow material sufficient suitable yellow pigment in accordance with BS 3262 shall be
substituted for all or part of the titanium dioxide to comply with the performance requirements
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of this specification.
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11 The binder shall not contain more than 5 % of resin or other acidic material. It shall consist
mainly of hydrocarbon resins plasticised with mineral oil.
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12 The resins used shall be of a colour at least as pale as Grade WG resin. It shall have an acid
value not greater than 2, and must pass the heat stability test described below.
13 The oil used as plasticiser shall be a mineral oil with colour and viscosity as defined in
paragraph 7a (ii) of BS 3262: Part 1; i.e., at least as pale as grade 4 on the P-R-S- Shellac
and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 C viscosity. In addition, when heated for
16 hours at 150 C it shall not darken excessively.
14 The softening point of the binder shall be used only as a guide to quality control, and the
behaviour of the thermoplastic shall be judged from the performance tests described below.
15 The viscosity of the melted binder at the spraying temperature must be such as to produce a
thermoplastic mix of the required spraying properties.
16 The temperature limits imposed by BS 3262: Part 1 for materials based on resin shall not
apply. Temperatures up to 220 C may be used; at these temperatures the material shall not
discolour in the time required for its use.
17 Containers shall be made of a material which does not contaminate the contents and will
protect the contents from contamination.
18 The capacity of each container shall be not less than 25 kg or more than 100 kg.
19 Each container shall be clearly marked with the manufacturer's name, batch number and
date of manufacture.
20 Testing for the composition of the material and the grading of the aggregate shall be carried
out in accordance with the methods in BS 3262 except as modified by this part of the
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specification. The composition of the laid material as found on analysis shall comply with
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Table 13.2 & Table 13.3;
Table 13.2
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Proportion of Constituents
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Percent by Weight
Constituent
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Binder 18 22
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Aggregate, pigment and extender and ballotini 78 82

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Table 13.3
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Grading of Combined Aggregate Pigment and Extender

Percent by Weight
BS Sieve (mm)
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Minimum Maximum
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0.850 100 -
0.600 75 95
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0.300 35 65
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0.075 25 35
13.3.3 Application of Thermoplastic
1 Application shall be by mobile sprayer, either hand-propelled or self-propelled.
2 The road surface shall be dry, and free of loose, detritus mud, or other extraneous matter.
3 All existing markings of more than 1 mm thick shall be removed completely before new
markings are applied.
4 A tack coat should not be necessary when the thermoplastic is applied to carriageways.
Where it is considered necessary to use a tack coat, this shall be rubberised type
recommended by the manufacturers of the thermoplastic material.
5 In addition to the ballotini included in the mix, an additional quantity of glass beads shall be
sprayed on to the hot thermoplastic line at the time of application. The rate of application
2
shall be at the rate of about 0.5 kg/m .
6 The thermoplastic material shall be applied in intermittent or continuous lines of thickness

1.5 mm  0.3 mm.
7 For special lettering, arrows or symbols the material shall be applied by hand methods.
8 The finished lines shall be free from raggedness at all edges and be true in place with the
road surface.
9 The upper surface shall be level, uniform and free from streaks, blisters, lumps and other
defects.
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13.3.4 Performance Requirements and Testing
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1 The thermoplastic material shall meet the requirements of Table 13.4:
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Table 13.4
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Properties of Thermoplastic Material
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Property Minimum Maximum
3
Density, g/cm 2.0 approx. -
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Open flashpoint °C 230 -

Softening point (ring and ball BS 2000 Part 58), °C 95 105
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Luminance 65 -
Luminance (Yellow) 45 -
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Flow resistance No Slump -

Flow resistance after 48 h at 40 °C - 25
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Abrasive wear 9/100 revs - 0.3

Skid resistance 45 -
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2 Testing of thermoplastic material shall be as described below. All specimens shall be

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prepared by carefully heating a representative sample to a temperature of (softening point +

50 C) whilst stirring thoroughly to avoid segregation. The molten material shall be used
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without delay.
3 Heat Stability Luminance Test: The material shall be cast on to a suitable flat, glossy surface
coated with a colourless release agent to give a slab 100 mm square by 3 mm thick. The
luminance of the cast face, with reference to that of a block of magnesium oxide (luminance
factor l00) shall be measured with the sample illuminated by a tungsten light source at an
angle of 45  viewed at right angles by a selenium barrier layer photoelectric cell.
4 Flow Resistance Test: The material shall be cast into a conical mould having an apex angle
of 60  and a vertical height of 100 mm. After cooling and setting for 24 h the cone shall be
removed from the mould, placed on a flat level surface and maintained at a temperature of
23 C ± 2 C for 48 h.
5 Impact Test: A 3 mm thick coating of material shall be prepared as a screed on a Monel alloy
panel 1.25 mm thick, previously coated with rubberised bitumen emulsion. The impact
instrument, a 4.7 kg weight, shall be dropped vertically through 250 mm on to the surface of
the panel, striking the surface with a hemispherical indentor of radius of 6 mm. The panel
shall be retained by a metal block drilled to allow the indentor to strike the panel, with the
depth of indentation limited to 2 mm. Five panels shall be tested and no fracture shall result
from impact. A crack not longer than 2 mm will be accepted provided there is a smooth
indentation in the material.
6 Abrasive Test: A 3 mm thick coating of material shall be screeded on to a Monel alloy panel
and subject to wet (water lubricated) abrasion at 23 C on a Taber Model 503 standard
abrasion tester using H-22 Calibrade wheels, refaced between tests. The loss in weight after
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two successive tests of 100 revolutions shall be recorded and the average taken as the
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abrasive wear. The abrasive wear shall be less than the figure in Table 13.4.
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7 Skid Resistance: A 100 mm wide line of material 1.5 mm thick shall be screeded on to a flat,
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level base for a minimum length of 800 mm. After cooling to ambient temperature the skid
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resistance shall be measured using the TRRL Portable Tester as described in Road Note 27.
Measurements shall be made on different parts of the specimen, corrected for temperature
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effects, and the average recorded.
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13.3.5 Protection of Pavement Markings

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1 The Contractor shall control the traffic in such a manner as to protect the freshly marked
surface from damage. The traffic control shall be so arranged as to give minimum
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interference to the travelling public. Signs, barricades, flagmen and control devices shall be
supplied by the Contractor and a system of spaced warning flags or blocks shall be used to
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protect the fresh marking until it has dried as required. Any lines, stripes or markings which
become blurred or smeared by the traffic shall be corrected by the Contractor.
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13.4 TEMPORARY ROAD MARKING

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13.4.1 ROAD MARKING PAINT

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1 The use of road marking paint shall be restricted to traffic diversions or for other uses as
directed by the Engineer.
2 Road marking paint shall be by an approved manufacturer. It shall be suitable for applying by
brush or mechanical means to cement, concrete or bituminous pavement to give a
chemically stable film of uniform thickness and shall be chlorinated rubber, one pack epoxy
or alkyd based.
3 White paint shall contain not less than 6 % by mass of titanium dioxide as a pigment,
conforming to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1
4 Yellow paint shall be standard colour BS 381C No. 355, except where an alternative shade
has been designated, and contain not less than 6 % by mass of a suitable yellow pigment.
5 The paint shall be supplied fresh and ready for use in sealed containers and stored in
accordance with the manufacturer's instructions. The paint shall be applied without the use of
thinners or other additives.
6 Paint shall be applied at a covering rate recommended by the manufacturer and approved by
the Engineer.
7 Where markings are to be reflectorised with ballotini it shall be sprayed uniformly on to the
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wet paint film at the rate of 400-500 g/m . Ballotini shall be graded to comply with the
requirements of BS 6088.
8 Road marking materials shall only be applied to surfaces which are clean and dry. Markings
shall not be ragged at their edges and shall be uniform and free from streaks. Carriageway
lane and edge lines shall be laid by approved mechanical means to a regular alignment.
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13.4.2 ADHESIVE ROAD MARKING STRIP
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1 For temporary diversions the use of self adhesive proprietary marking strips will be permitted.
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2 Self adhesive proprietary road marking strips shall be of the details and dimensions shown
on the drawings.
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3 The strips shall have a metallic backing that peels of and shall have reflective properties by
the incorporation of ballotini.
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13.4.3 REMOVAL OF ROAD MARKINGS

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1 Where it is necessary to remove existing thermoplastic road markings the material shall be
completely removed by sand blasting or other abrasive methods.
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2 Care shall be taken to avoid damaging the wearing course surface during this operation.
3 Any damage caused to the wearing course shall be made good to the satisfaction of the
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engineer.
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4 The painting over of old road markings with black paint shall not be permitted.
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13.5 REFLECTIVE STUDS

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13.5.1 General
1 Reflective road markers shall be smooth, pressure moulded aluminium alloy, complying with
BS 1490 with lenses to meet the performance requirements of this specification. They shall
be capable of withstanding the climatic conditions of Qatar and be maintained free. A
performance guarantee of five years is required.
2 The Road stud shall measure 130 mm x 115 mm x 25 mm when seated on the road surface.
Exact size of the road stud shall be as designated.
3 The shaft shall be "Anti-Twist/Hot-Tite", 76 mm long.
4 The slope of the reflecting face shall be 20.

5 The enveloping profile of the head of road studs shall be smooth and the studs shall not
present any sharp edges to traffic.
6 The body of the stud shall be constructed in one integral part.
7 The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel
flats, the flats on the alternative ribs being at 90  to each other to prevent rotation of the stud
when located in the road surface.
8 The studs shall be constructed in aluminium alloy to BS 1490 to provide a robust and durable
location for the lenses. The alloy shall have the characteristics listed in Table 13.5.
Table 13.5
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Composition of Alloy for Road Studs
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Composition Minimum (%) Maximum (%)
Copper - 0.1
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Silicon - 13.0
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Iron - 0.6
Manganese - 0.5
Nickel - nt 0.1
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Zinc - 0.1
Lead - 0.1
Tin - 0.1
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Titanium - 0.5
Aluminium - Remainder
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The Contractor shall submit mill certificates for the material showing the actual composition.
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9 Reflective studs mechanical and physical properties shall comply with the Table 13.6
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requirements:
Table 13.6
Mechanical and Physical Properties of Reflective Studs
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Mechanical Properties Minimum

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0.2 proof stress test, N/m 120
2
Tensile Strength, N/mm . 280
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Elongation, mm 2-5
Physical Properties Minimum
Specific gravity 2.65

Method of Casting Injection
Corrosion rating Excellent
Brinell hardness number 55 - 60
13.5.2 Reflectors
1 The reflectors shall be rectangular in shape. The rectangular reflective unit shall be firmly
located into a recess within the body of the stud such that the reflective face is established at
the correct orientation. A sample of the proposed reflective studs shall be submitted for the
Engineer’s approval.
2 The Optical Performance (specific intensity) of each crystal reflecting surface shall not be
less than the values listed in Table 13.7.
Table 13.7
Optical Performance of Reflectors
Observation Angle, ° 0.3 0.5 1.0 2.0
Entrance Angle, ° 5 10 10 15
Specific Intensity 160 100 27 3
Specific Intensity 120 72 20 2
3 For yellow reflectors the specific intensity shall be 50% of the value for crystal. For red and
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green reflectors the specific intensity shall be 20% of the value for crystal.
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4 The colour limits of the reflector(s) when illuminated by CIE standard illumination A, with an
entrance angle V= 0 , H= 5  L or R, and an observation angle of 0.3  shall comply with the
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requirements given in the following paragraphs.
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White (uncoloured) reflectors shall not produce a selective reflection; that is to say, the
trichromatic co-ordinates X and Y of the standard illuminant A used to illuminate the reflector
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shall undergo a change of more than 0.91 after reflection by the reflector.
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6 Red reflectors shall have chromaticity co-ordinates which lie within the area formed by the
straight lines defined by the following pairs of points, 1 and 2, 2 and 3, the spectrum locus,
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and the line joint the ends of the spectrum locus:

Co-ordinate Point 1 Point 2 Point 3
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X 0.665 0.657 0.730

Y 0.335 0.335 0.262
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7 Amber reflector shall have chromaticity co-ordinates which lie within the area formed by the
straight lines defined by the following pairs of points, 1 and 2, 2 and 3, 3 and 4, and the
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spectrum locus:-
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Co-ordinates Point 1 Point 2 Point 3 Point 4

X 0.330 0.228 0.321 0.302
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Y 0.385 0.351 0.493 0.692

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8 Compliance with the colorimetric requirements shall normally be verified by means of a visual
comparison test. If any doubt remains after this test, compliance shall be verified by the
determination of the trichromatic co-ordinates as defined in the proceedings of the 1951
meeting of the International Commission (CIE).
13.5.3 Reflectivity
1 A sample of the road stud shall be submitted by the Contractor and relevant technical
information, catalogues supplied by the manufacturers shall accompany the sample.
2 The reflectivity of the stud when new shall well exceed minimum standard as laid down in BS
873 and meet typical values as shown below:
Table 13.8
White Reflectors Tested to BS 873
CIL Value CIL Value
(mod/1x) (mod/1x)
Orientation
Typical Minimum
Observation angle 2  Entrance Angle 15  L and 15  R. 5-7.5 2

Observation Angle 2  Entrance Angle 10  L and 10  R 26.5-30 10
Observation Angle 0.5  Entrance Angle 10  L and 10  R 59-93 15
Observation Angle 0.3 Entrance Angle 5  L and 5  R 100-190 20
Table 13.9
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Amber Reflectors Tested to BS 873
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CIL Value CIL Value
(mod/1x) (mod/1x)
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Orientation
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Typical Minimum
Observation angle 2  Entrance Angle 15  L and 15  R. 3-4 1.0
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Observation Angle 1  Entrance Angle 10  L and 10  R. 10-20 5.0
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Observation Angle 0.5  Entrance Angle 10  L and 10  R. 20-50 7.0
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Table 13.10
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Red Reflectors Tested to BS 873

CIL Value CIL Value
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(mod/1x) (mod/1x)
Orientation
Typical Minimum
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Observation angle 2  Entrance Angle 15  L and 15  R 1.5-2.0 2.0

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Observation Angle 1  Entrance Angle 10  L and 10  R 4.5-7 10.0

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Observation Angle 0.5  Entrance Angle 10  L and 10  R 10-20 15.0

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13.5.4 Installation of Reflective Studs
1 Reflective studs shall be installed and anchored to the pavement as follows:
(a) Drill a hole into the asphalt pavement to the dimensions recommended by the
manufacturer. Ensure that the hole is free of dust and also the pavement surface
within a radius of 200 mm of the hole is free from debris and dust.
(b) Fill the hole to overflow with the two part epoxy adhesive of the type specified in clause
10.6.2.
(c) Immediately after pouring the grout, the road stud shall be inserted into the hole and
the reflective face aligned to the oncoming traffic. The road stud shall be firmly
embedded into the ground ensuring a good bed of grouting compound under the road
stud and solid fixing. Protect the installed marker until the epoxy adhesive has
completely set.
(d) Clean off any surplus grouting and protect the road stud from traffic for approximately
60 minutes.
13.6 NON-REFLECTIVE STUDS
13.6.1 General
1 Non-reflective road studs shall be ceramic and of approximately 100 mm diameter at the
base, the studs shall consist of a heat-fired, vitreous ceramic base and a heat fired opaque
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smooth matte surface.
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2 The colour of the studs shall be white unless otherwise designated. The base of the stud
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shall have a rough surface to ensure a good bond to the road.
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3 The adhesive used for the installation of non-reflective ceramic studs shall be a two part
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epoxy or other material recommended by the manufacturers and tested under the climatic
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and traffic conditions prevalent in Qatar.
4 The non-reflective ceramic studs shall conform to the dimensions and shapes shown on the
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drawings and shall be installed at the location indicated on the drawings or where designated
by the Engineer.
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5 The studs shall be ceramic manufactured and shall consist of a heat-fired, opaque, glazed
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surface. The glazed surface shall not be present on the bottom of the studs which will be
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cemented to the road surface. The outer surface of the studs shall be smooth except for
purpose of identification, and all edges exposed to traffic must be convex and the radius
nearest the edge may be less. Any change in curvature shall be gradual. The bottom
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surface of the marker shall be of a roughness comparable to at least that of a fine grade of
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sandpaper, and shall be substantially free form gloss or substance that may reduce its bond
to the adhesive.
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6 The body of the marker shall be white.

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7 Brightness will be measured with equipment conforming ASTM E97 using a Brightness
Standard of 75%. The minimum weight of the marker shall be 125 grams.
8 A random sample of 5 buttons shall be subjected to the compressive load test. The average
compressive strength of the 5 buttons shall not be less than 680 kg and no individual button
shall have a compressive strength less than 544 kg. The button shall be centered base
down, over the open end of a vertically positioned hollow metal cylinder. The cylinder shall
be 25.4 mm high, with an internal diameter of 76.2 mm and a wall thickness of 6.4mm. A
load necessary to break the button shall be at speed of 2.5 mm per minute to the top of the
button. In the event that the bottom of the marker is dimpled, a 2 mm layer of wood shall
insert between the base of the maker and the hollow cylinder. Should any of the samples
tested for strength fail to comply with this specification, 10 additional samples will be tested.
The failure of any one of the additional samples shall be cause for rejection of the entire lot or
shipment represented by the samples.’
13.6.2 Materials and Manufacture
1 The studs shall be produced from a combination of intimately mixed clays, shales, flints,
feldspars or other inorganic material which will ensure the required properties are met. All
studs shall be thoroughly and evenly matured and free from defects which affect appearance
or serviceability.
2 The studs shall be of uniform composition and free from surface irregularities cracks,
chipping, peeling spoiling, crazing and any other physical damage. The studs shall be precast
in the form of a single based spheroidal segment terminating in a rounded or squared
shoulder.
3 The height of the studs above road level shall be between 18 mm and 20 mm.
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4 Compliance of the studs with respect to appearance, shape, dimensions and compressive
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strength shall be determined in accordance with CML Method 14-97. In particular, they shall
exhibit an average compressive load at failure for each sample of 5 studs of not less than
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680 kg and no individual value shall be less than 544 kg. Furthermore, the water absorption
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shall not exceed 1.0% when tested in accordance with ASTM C373. And the glazed surface
of the stud shall not craze, spell, or peel when subjected to one cycle of the Autoclave test at
250 psi when tested in accordance with ASTM C424. nt
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5 The adhesive for reflective studs and non-reflective studs shall be a two component epoxy.
Each component shall be supplied in separate clearly marked containers and the time of use
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the contents of the two parts shall be thoroughly redispersed by mixing. Only complete
containers of each part shall be used and these shall be mixed thoroughly until a uniform
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colour is achieved with no streaks of individual colours. The blend of the two components of
epoxy thoroughly mixed together shall meet Table 13.11.
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Table 13.11
Specification for Epoxy Adhesive
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Property Value
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Gel time 5 to 30 minutes

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Minimum Tensile strength of 1.6 mm film between steel blocks cured 2

7 N/mm
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24 h at 21 °C tested at 21 °C
Shore hardness on 24 h sample at 21°C 70 to 80
Shore hardness on 24 h sample at 49 °C 30 minimum
Deformation temperature, °C 49 minimum
6 The Contractor shall submit recent test results that confirm the above properties of the
supplied adhesive are met.
7 The epoxy shall be used strictly in accordance with the manufacturer’s recommendation for
storage preparation, mixing and application. Any differences from the manufacturer’s
recommendations and this specification shall be referred to the Engineer.
8 The final colour of the epoxy adhesive shall be uniform grey unless designated otherwise.
13.6.3 Installation
1 All sand, dirt and extraneous material shall be removed from the mark location and the
surface cleaned and abraded. Cleaning shall be by compressed air. In the case of adhering
material the application of heat or sand blasting will be required.
2 The surface shall be completely dry for the application of the adhesive.
3 The base of the supplied stud shall be free of any wax or grease from the manufacturing
process. Any such wax or grease shall be sanded off the bottom of the marker.
4 The adhesive components shall be stored at the temperature recommended by the
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manufacturer both before use and during application. The two components of the adhesive
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shall be added to each other just before use, any unused mixed adhesive shall be discarded
when catallic actions cause stiffening and reduction of workability or balls of gelled resin
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formed in the container.
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5 The mixed adhesive shall be applied to the prepared pavement area to be covered by the
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marker and the stud pressed onto the adhesive so as to squeeze out a small bead of
adhesive around the periphery of the stud.
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6 The Contractor shall carry out a trial outside of the permanent works to establish the
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approximate amount of adhesive required per marker and application on the works shall be
carried out to this quantity.
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7 The studs shall not be fixed to the pavement where asphalt has been laid within the last 14
days unless otherwise directed by the Engineer. The studs shall be spaced and aligned as
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designated or as per the Qatar Traffic Control Manual. The tolerance for placing shall be not
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more than  10 mm.
8 Where studs are to be applied to pavement where the road is to be opened to public traffic
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shortly after placing, the preheating of the roadway surface to permit a rapid set is permitted.
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In such cases, the procedure followed shall be as recommended by the supplier of the epoxy
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adhesive and as approved by the Engineer.

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9 On roadway sections that are not opened to public traffic no preheating of the studs or road
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surface is required as long as the required bond strength of 12 kg/cm can be achieved in
less than 3 h.
END OF PART
Part 14: Works in Relation to Services
14 WORKS IN RELATION TO SERVICES ........................................................ 2
14.1 GENERAL ...................................................................................................... 2

14.1.1 Scope 2
14.1.2 References 2
14.1.3 Submittals 2
14.1.4 Notification to Service Authorities & Statutory Bodies 3
14.2 SERVICES GENERALLY .............................................................................. 3
14.2.1 General 3
14.2.2 Safety 4
14.2.3 Marking Services 4
14.2.4 Location of Existing Services 5
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14.2.5 Protection of Services 5
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14.2.6 Relocation of Services 6
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14.2.7 Services Ducts 7
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14.2.8 Excavation for Ducts 7
14.2.9 Bedding and Laying of Ducts 8
14.3 nt
PARTICULAR REQUIREMENTS .................................................................. 8
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14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks
Affairs, QGEWC (ENA) 8
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14.3.2 Qatar General Electricity and Water Corporation, Water Networks

Affairs, QGEWC (WNA) 10
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14.3.3 Telecom Provider 10

14.3.4 Qatar Petroleum (QP) and Qatar Gas 12
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14.3.5 PWA, Storm water and Groundwater 13

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14 WORKS IN RELATION TO SERVICES

14.1 GENERAL
14.1.1 Scope
1 This Part includes the provision of new services and the seeking, protection, diversion and
relocation of the existing services for the following service authorities:
Qatar General Electricity & Water Corporation (QGEWC)
Telecom Provider
Qatar Petroleum (QP) and Qatar Gas
Public Works Authority (PWA)
Urban Planning and Development Authority (UPDA)
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Local Municipality
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This Section Part 1 General
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Part 3 Earthworks
Part 17 Road Drainage
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Section 1 General
Section 5 Concrete
Section 20 Drainage Works For Buildings
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14.1.2 References
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1 The following standards and reference documents are referred to in this Part:
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BS 1377......................Methods of tests for soils for civil engineering purposes

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BS 2484......................Straight concrete clayware cable covers

BS 2782......................Methods of testing plastics.
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14.1.3 Submittals
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1 The Contractor shall prepare and submit records and sketches showing position, levels and
types of each existing service including manholes, joint boxes, inspection chambers and
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connections. These records shall be maintained in the form of a daily diary.
2 The Contractor shall prepare and submit shop drawings for utility protection work and obtain
the approval of the appropriate Authority before beginning construction.
3 Samples of proposed ducts shall be submitted to the Engineer for his approval beforehand.
4 The Contractor shall prepare and maintain up-to-date drawings for each service authority
giving details of each duct laid including precise location, level, number and type, and these
drawings are to be submitted to the Engineer.
5 The Contractor shall keep accurate records of the arrangement, positions and details of all
works constructed by him as Record Drawings. The details, format, extent and procedures
for the preparation and submission of the record drawings shall be in accordance with
Section 1.
14.1.4 Notification to Service Authorities & Statutory Bodies
1 All works in relation to services shall be carried out by a contractor or subcontractor

prequalified and approved by the concerned service authority. Proof of such approval shall be
required in writing before the start of Works on the Site. The name of any subcontractor to be
used shall be as designated.
2 No work concerning services will be started without having first informed and obtained
approval of the concerned service authorities. Before opening the ground for any purpose,
the Contractor must notify all concerned parties by issue of formal "Notice of Intent" and must
obtain information by formal notice regarding the location of all services. The complete
responsibility for obtaining this information rests with the Contractor. "Notices of Intent" shall
be circulated to all concerned parties including those listed in Clause 11.1.1:
Qatar General Electricity & Water Corporation (QGEWC)
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Telecom Provider
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Qatar Petroleum (QP) and Qatar Gas
Public Works Authority (PWA)
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Urban Planning and Development Authority (UPDA)
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Local Municipality
3
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Prior to commencing any work on excavation in a roadway the Contractor shall obtain the
approval of the Traffic Police. All excavations in a roadway shall be carried out in accordance
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with PWA road opening procedures.
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4 Drawings and notices shall be sent in duplicate one of which shall be retained by the
addressee and the other returned to the sender duly marked to show underground services.
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"Notice of Intent" will be given 14 days in advance of starting the proposed Works. In the
event that the work is not started within eight weeks of the date of the "Notice of Intent", it will
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be deemed to have lapsed. A further Notice of Intent will then be submitted. The Contractor
shall furnish copies of the above Notices of Intent to the Engineer.
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5 The Contractor's attention is particularly drawn to the procedures to be followed concerning

existing services and service diversions laid down in all current administrative orders of the
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service authorities.
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14.2 SERVICES GENERALLY

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14.2.1 General
1 The Contractor shall acquaint himself with the position of all existing services and shall obtain
clearance from the concerned service authority before commencing any work in a particular
area. Written evidence of such clearance shall be provided to the Engineer by the Contractor.
2 The position, types of ducts, pipes, cables, manholes and related structures are designated,
but the final location will be determined on site by the Contractor and submitted to the
Engineer for approval after having consulted with the concerned service authorities.
3 All concrete works shall conform to the requirements of Section 5.
4 The Contractor will be fully responsible for ensuring observance of the requirements of this
clause by his subcontractors.
5 Where any utility or service works are to be constructed under a separate contract by the
Engineer within the Site and concurrent with the execution of the Works, the Contractor shall
co-operate with the other contractor and shall co-ordinate his construction operations to avoid
interference with the other contractor's operations.
6 Any public or private service for water, electricity, drainage, or other utility, affected by the
Works shall not be interrupted without the written permission of the Engineer. Such
permission will be withheld until suitable approved permanent or temporary alternative
services have been provided by the Contractor or by the owner of the utility or his agents.
7 For temporary traffic diversions as may be required for the construction of road crossings, full
liaison with the Municipality and Police shall be required as well as compliance with the
requirements of the PWA road opening procedures.
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8 The Contractor shall be responsible for following each service authorities inspection and
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testing procedures.
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9 The Contractor shall be responsible for liaison with each service authority to obtain their
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approval for the completion of the works.
14.2.2 Safety
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1 The Contractor shall be responsible for public safety during execution of work. He shall take
all measures, including, where necessary, the provision of ropes, picket fences, and other
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temporary barriers on the sides of trenches and excavations with warning lights.
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2 The Contractor shall arrange for night watchman and any other measures required to ensure
the safety of the public.
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3 The Contractor will be held responsible for any damage to property or injury to persons due
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to his negligence. Any instruction from the Engineer concerning the safety aspects of the
work must be carried out immediately, but the Contractor shall remain responsible for the
adequacy of the safety measures.
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4 The Contractor shall take into account the current laws regarding the safety of service lines,
together with any amendment or additions thereto. The Contractor shall be responsible for
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locating or verifying the location of existing services, liaison with the various service
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authorities and complying with the above.
14.2.3 Marking Services
1 All services shall be provided with continuous warning tapes with the requirements of the
following paragraphs.
2 The Contractor shall install approved warning tapes during backfilling work over buried pipes,
cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for
identification according to the requirements of the concerned service authority.
3 Warning tape shall be approved high quality, acid and alkali-resistant polyethylene film
250 mm wide, and with a minimum thickness of 150 microns. Tape shall have a minimum
tensile strength of 125 kg/cm2 longitudinally and 105 kg/cm2 laterally with an elongation
factor of 350 %.
4 Tape shall be printed with 50 mm high black lettering, alternatively in Arabic and English. The
complete wordings shall be repeated every 2 m along the tape. The colours shall be vivid,
glossy and permanent with a life expectancy of 40 years.
5 Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape
relating to the top of service shall be in accordance with the requirements of the concerned
service authority.
6 Warning tapes over non-metallic services shall be backed with aluminium foil to facilitate
detection.
14.2.4 Location of Existing Services
1 The positions of all designated public and privately owned services have been based on the
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records of various service authorities and must be regarded as approximate.
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2 The positions designated for existing services are for informational purposes only and do not
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necessarily show exact locations, depths, spacings, or the presence and location of smaller
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services such as house connections which are not normally designated.
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The Contractor shall verify this information and satisfy himself as to the exact nature and
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position of all such apparatus. The Engineer does not guarantee the accuracy of the
designated information, and no warranty is given or implied.
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4 The Contractor shall verify the position of services by digging trial trenches and pits. If ducts,
pipes, cables and manholes which are not designated are found, the Engineer and the
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concerned service authority shall be informed as soon as possible. The concerned service
authority will then instruct on the action to be taken, if any.
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5 The Contractor shall excavate by hand, take trial pits at regular distances and also at all road
intersections to locate existing services, their number, depth and route direction. As these
services are located the Contractor shall prepare record drawings indicating the
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aforementioned information which shall be submitted to the Engineer.

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14.2.5 Protection of Services

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1 The Contractor shall take any and all measures reasonably required by any public or
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concerned service authority for the support and full protection of all mains, pipes, cables and
other apparatus during the progress of the Works, and shall construct and provide to the
satisfaction of the concerned service authority, all works necessary for the prevention of
damage or interruption of services.
2 The protection of the existing services shall be carried out before the earth work starts in the
vicinity of the services to be protected.
3 If some services have already been protected by the various Departments, no protection will
be carried out under this Contract, but such protection can be extended or upgraded as
instructed by the Engineer on Site after having consulted with the concerned service
authority.
4 If in the execution of the Works, by reason of any subsidence caused by, or any act of
neglect or default of the Contractor, any damage to any apparatus or any interruption of, or
delay to, the provision of any service is caused, the Contractor shall report it to the Engineer
immediately and bear and pay the cost reasonably incurred by the service authority
concerned in making good such damage and shall make full compensation to the authority
for any loss, sustained by reason of such interruption or delay.
5 All protected services, existing ducts found or newly laid ducts shall be marked with markers
of approved of size and type as designated. The location of markers shall be as designated.
No asphalt course will be laid unless the ends of the ducts or protected services have been
exposed and marked with markers.
6 The Contractor shall, at all times during the progress of the works, afford facilities to properly
accredited agents of any concerned service authority for access to all or any of their
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apparatus situated in or under the site, as may be necessary for inspecting, reporting,
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maintaining, removing, renewing or altering such apparatus in connection with the
construction of the Works or any other purpose whatsoever.
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14.2.6 Relocation of Services
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The Contractor shall relocate certain utilities to service reservation areas as designated. This
work may only include constructing necessary protective housing such as box culverts, slabs,
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and concrete encased sleeves in the service reservation areas for utility lines to be relocated.
Or this work may include necessary protective housing as described above and, in addition,
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the relocation of specific utility lines to the service reservation areas.

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2 In both cases the Contractor shall complete the necessary survey to establish the lines and
levels, prepare shop drawings and submit them to the Engineer for his review. The
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Contractor shall obtain approval from the concerned service authority before commencing
this work.
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3 After existing services, according to the Engineer's instruction, have been exposed and if
according to the opinion of the Engineer and after approval of the concerned service
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authorities it is found necessary to proceed with the lowering or diversion thereof, the
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Contractor shall proceed with the relevant excavation in co-ordination with the said
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authorities.
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4 The Contractor shall maintain records of such excavation in a form acceptable to the
Engineer. Two copies of such records shall be submitted to the Engineer on a weekly basis
or as agreed with by the Engineer.
5 All materials removed shall be disposed of by the Contractor as designated.
6 When directed by the Engineer, all such excavations shall be backfilled with suitable material,
placed and compacted as designated.
7 The Contractor shall place fill material and compact with care to avoid damage to the existing
services. The Contractor shall be responsible for any and all damages caused by his
construction operations.
8 The works relevant to the lowering of existing services will be started as soon as, according
to the Engineer, all the necessary precautions have been taken to prevent any injury to
person or damage to property or services.
9 The excavation for lowering existing services shall be performed by hand down to the
elevation indicated by the Engineer and the concerned service authority.
10 At all times the Contractor shall provide and maintain access to the adjoining properties to
the satisfaction of the Engineer.
14.2.7 Services Ducts
1 Service ducts shall be provided as designated so that future services can pass through them
without disturbing road construction.
2 The Contractor shall supply, unless otherwise designated, and install all the necessary
service ducts required for the project. The duct material shall be as designated.
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3 Road crossing ducts shall extend beyond the road or shoulder line at each side of the road
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as designated.
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4 To prevent earth blocking the ducts, the openings at both ends are to be protected with
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appropriate blanking caps.
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In general, all duct laying work is subject to the approval of the Engineer and any particular
requirements of the concerned service authority.
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6 The Contractor shall after completing each duct, make the necessary arrangements with the
service authority for testing and acceptance of the work. As a minimum this shall involve the
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verification of the duct by rodding or pulling through a mandrel.

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14.2.8 Excavation for Ducts

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1 The trench shall be excavated to the designated width and depth.

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2 When appropriate, the excavation for the road crossing and laying of ducts, concreting and
related work shall only be carried out on half the width of the road at one time, the other half
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being left available for traffic. In this case the necessary traffic warning signs on self-
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supporting tripods or cones shall be provided well ahead of the duct crossing work and all
care and attention exercised to avoid risk of traffic accidents during preparation and
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execution of the work.

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3 All trenches and other excavation shall be maintained in a dry condition and the Contractor
shall arrange a suitable dewatering system for any dewatering involved, in agreement with
the Engineer, to keep the working place clean and dry.
4 The sides of pits and trenches shall be vertical and adequately supported at all times.
Excavations may if considered necessary be battered with a safe slope, but only with the
Engineer's written permission.
5 Where ducts are laid under any area of the road construction, the bottom of the excavation
shall be completed to a density of 95 % of the maximum dry density, as determined by BS
1377 Test 13 or as otherwise approved by the Engineer.
6 Excavated material shall, if found unsuitable as defined in Part 3 of this Section, be disposed
of to an approved tip and replaced with suitable material. All surplus suitable excavated
material shall be used in road construction or disposed of in an approved manner.
7 Where split ducts are required for existing services crossing the Works, hand excavation
shall be carefully undertaken until the position of the service to be protected is fully exposed.
14.2.9 Bedding and Laying of Ducts
1 As soon as possible after trench excavation, ducts of the required diameter shall be laid and
jointed as designated and in accordance with the manufacturer's instructions.
2 Ducts shall be laid to the designated lines and levels with the required depth of cover. Where
the designated minimum cover cannot be achieved, or as otherwise directed by the Engineer,
they shall be bedded and surrounded with 150 mm of grade 20 concrete.
3 Unless surrounded in concrete, ducts shall be bedded on a 150 mm thick layer of well graded
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sand of maximum particle size 5mm and fully surrounded with sand to a depth of 150 mm
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above the duct barrel, well packed and tamped. Filling with suitable material above this level
shall be free from large stones. For multiple ducts, the spaces between ducts are to be filled
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with compacted sand and the ducts surrounded to a depth of l50 mm above the uppermost
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layer. Trench backfill shall be compacted to the designated requirements.
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Ducts shall be cut by the Contractor as necessary only at right angles to their length using a
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saw in a simple cutting guide. The inside cut edges Shall be thoroughly rounded off or
dressed before installation to prevent damage to cables drawn through the ducts.
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5 In kerbed areas of new roadway duct markers shall be used. Duct marker shall be of
concrete construction, in-situ or precast depending on the location, as per the designated
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details complete with approved abbreviation cast thereon. The finished product shall be solid
in appearance, free of segregation, honeycombing broken edges and other defects.
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14.3 PARTICULAR REQUIREMENTS

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14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC
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(ENA)
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1 All of the works associated with electricity supply shall be carried out in accordance with the
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latest specifications for materials, excavation and backfill, cable laying and jointing, as issued
by the QGEWC (ENA). Contractors are deemed to be in possession of the latest QGEWC
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(ENA) specifications.
2 All QGEWC (ENA) MV, HV and EHV works shall be carried out by a Contractor or
subcontractor prequalified and approved by the QGEWC (ENA). Proof of such approval shall
be required in writing before the start of Works on the Site, and the name of any
subcontractor to be used shall be as designated. All cable jointers to be used on the Contract
shall be required to undertake and pass a trade test conducted by QGEWC (ENA).
3 The Contractor shall comply with all requirements of the Police Department for marking,
lighting and protecting excavation. It is the responsibility of the Contractor to ascertain the
requirements of the Police Department and to comply fully with these requirements.
4 Where carriageway works and road crossings are performed the Contractor shall provide
steel plates of sufficient size and quality to permit the safe passage of traffic and the plates
shall be so placed (and if necessary fixed) to permit reasonable traffic flow.
5 All doorways, gates and entrances shall be kept clear with full access. Where excavations
impede pedestrian access crossing boards shall be provided. Crossing boards shall be 1250
mm wide with a handrail on both sides 1 m in height and guard-rails on both sides at
vehicular and pedestrian access to premises. Ducts will not be installed at entrances to
premises except on the express instruction of the Engineer.
6 Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not
possible, the material shall be removed from site and returned for backfilling on completion of
cable laying. In cases where the excavated material is not to be used for backfilling trenches
it must be removed from site on the same day as it is excavated.
7 QGEWC (ENA) will require to carry out inspections at the following stages:
(a) Completion of excavations.
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(b) Completion of bedding of trench before cable installation.
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(c) Cable installation.
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(d) Completion of surround over cables and installation of cable tiles.
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(e) Upon completion of reinstatement.
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The Contractor must not progress from one stage to the next of the above without the
approval of QGEWC (ENA) and the Engineer. The Contractor shall be responsible for
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arranging inspections by QGEWC (ENA) to suit his programme of works.
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9 Where materials are to be supplied by the Contractor, the requirements described in the
following paragraphs shall apply.
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10 Materials shall be ordered in accordance with the specifications issued by QGEWC (ENA).
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11 For works involving the use of high voltage overhead cables Contractors shall comply with
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the requirements of QGEWC circular no 6.
12 Specifications and the details of the proposed supplier shall be submitted to QGEWC (ENA)
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for approval before a firm order being placed.

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13 On delivery of materials to Qatar, QGEWC (ENA) inspectors shall be given the opportunity to
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inspect the materials before their use.

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14 The Contractor shall supply all cables and jointing materials for the works unless expressed
stated to the contrary in the contract documentation. Cleaning materials, protection tiles,
warning tape, and other materials shall be supplied by the Contractor.
15 The Contractor is responsible for all liaison with QGEWC (ENA) in respect of programming
the installation and commissioning of the complete electrical system. He shall ensure that
QGEWC (ENA) are at all times kept informed of the current progress of the civil works on the
Site and that his approved electricity supply subcontractor programs the cable laying works in
the designated sequence in accordance with the approved programme.
16 The Contractor shall provide and install concrete cable tiles over all 66 kV cables. The cable
tiles shall be of the designated size and form. Samples must be provided for approval by
QGEWC (ENA) and the Engineer, and satisfy a test of impact strength in accordance with BS
2484.
17 For cables of 132KV and above the measures for protection of the cable shall be as per the
requirements of QGEWC.
18 Cable tiles shall be installed over all 11,000 volt cables. Cable tiles shall be manufactured
from recycled polyethylene or similar with a minimum thickness of 12 mm, length 1 m, width
(minimum) 24 mm, tensile strength 8.40 N/mm2 as per BS 2782, Method 320 C.
19 The tiles shall be marked as designated. The cable tiles must be supplied complete with any
pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC
(ENA) and the Engineer for approval before use.
20 The Contractor shall liaise directly with QGEWC (ENA) regarding the removal of existing
cables and shall not, under any circumstance, commence removal of cables until QGEWC
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(ENA) have verified such apparatus as being redundant.
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21 Removal of cable shall only be carried out in the presence of a QGEWC (ENA) engineer.
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22 The Contractor shall arrange uplift of empty cable drums from QGEWC (ENA) Stores and
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shall return all recovered cables neatly coiled on the drums provided.
23 nt
Ducts are to be supplied by the Contractor. They shall be of high impact resistant PVC of
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internal diameter 150 mm or 100 mm as designated, minimum wall thickness 3.6 mm (for
150 mm) or 2.4 mm (for 100 mm). Samples must be provided for approval by the Engineer
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before use.
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14.3.2 Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC
(WNA)
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1 All of the works associated with water supply shall be carried out in accordance with the
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latest General Specifications for Main Laying Contracts and Main Laying Materials, as issued
by the QGEWC (WNA) except as modified in this Part. Contractors are deemed to be in
possession of the latest specifications.
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2 All QGEWC (WNA) Works shall be carried out by a Contractor or subcontractor prequalified
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and approved by the QGEWC (WNA). Proof of such approval shall be required in writing
before the start of Works on the Site and the name of any subcontractor to be used shall be
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as designated.
3 The supply of the materials required to carry out the Works shall be as designated in the
contract documents. The Contractor will be responsible for the conveyance of all materials to
the site of the works.
14.3.3 Telecom Provider
1 All Telecom Provider works shall be carried out strictly in accordance with the Telecom
Provider Standard Specifications Telecom Provider WRK 4001 Underground Duct Laying
And Associated Works. Contractors are deemed to be in possession of the latest version of
the specifications.
2 All Telecom Provider works shall be carried out by a Contractor or subcontractor approved by
Telecom Provider. Proof of such approval shall be required in writing before the start of
Works on the Site and the name of any subcontractor to be used shall be as designated.
3 Telecom Provider will supply as 'free issue" all ducts for Road Crossings projects only. Other
projects will be charged for the ducts. All other materials required for any type of project shall
be supplied by the Contractor.
4 Trenches for Telecom Provider ducts through rock fill shall be lined with geotextile, complying
with the requirements of Part 16, Geosynthetics.
5 The Telecom Provider specification S. 006 shall be modified as described in the following
paragraphs.
6 The Supervising Officer shall mean the Civil/Cable Engineer from Telecom Provider, for the
purpose of superintending the work, or, where the context permits, the representative of such
officers.
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7 The concrete quality classes specified in Clause 202 of the Telecom Provider specifications
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shall be of the comparable classes in Section 5 as designated by the Engineer.
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8 Clause 105 of Telecom Provider Standard Specifications Telecom Provider WRK 4001
‘Underground Duct Laying And Associated Works’ should be read as:
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105 (a)
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“Backfill materials” means earth free from stone or loose earth, compacted in
two equal layers above the protection dune sand, and shall not leave voids to
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form a water course.
“Sand bed and surround” means dune sand, 75 mm below, above and around
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105 (b)
the duct.
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9 The Contractor shall consult Telecom Provider not less than one month before it is proposed
to commence work to ascertain whether any underground installations will be affected by the
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proposed works, in which event the Contractor shall make all necessary arrangements with
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Telecom Provider to safeguard the installations.
10 The Contractor shall give at least one week's notice in writing to Telecom Provider of the
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dates upon which it is intended to operate plant or equipment or carry out any work for which
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permission has been given in writing by Telecom Provider. Such operations of work shall only
be carried out in the presence at Telecom Provider unless notice shall be obtained in writing
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from Telecom Provider that they do not require to be present.

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11 Telecom Provider may require work to be executed on their installations during the period of
the Contract. The Contractor shall allow access to Telecom Provider’s Contractor or
workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
Telecom Provider and his own activities and when necessary shall amend his programme of
working to suit all requirements of Telecom Provider in connection with their diversion work
and shall keep the Engineer informed in writing of all arrangements made.
12 The Contractor shall locate and mark with suitable posts all Telecom Provider underground
installations that are within the area of the Works and shall ensure that such markers are
maintained in their correct positions at all times. The Contractor shall advise Telecom
Provider’s agent of any installation not found where designated, or found but not shown or
found damaged or subsequently damaged.
14.3.4 Qatar Petroleum (QP) and Qatar Gas
1 All of the works associated with Qatar Petroleum and Qatar Gas shall be carried out in
accordance with their latest specifications except as modified in this Part. Contractors are
deemed to be in possession of the latest specifications. Before beginning any work the
Contractor shall approach Qatar Petroleum and Qatar Gas and obtain a copy of their latest
specification relating to the Works.
2 All Qatar Petroleum and Qatar Gas Works shall be carried out by a Contractor or
subcontractor prequalified and approved by Qatar Petroleum and Qatar Gas. Proof of such
approval shall be required in writing before the start of Works on the Site and the name of
any subcontractor to be used shall be as designated.
3 When working near existing QP Gas/Oil facilities the following conditions shall be adhered to.
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All notices to be given to the Contractor shall be in writing and delivered by hand.
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4 A permit to work must be obtained for all work within fifteen (15) meters distance from all
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boundaries of existing facilities. These permits can be obtained from QP and twenty four (24)
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hours notice should be given to prevent delays.
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Mechanical or hydraulic rock breakers shall not be used adjacent to gas, oil or NGL pipelines.
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6 Should jackhammers be required within two (2) meters of any buried pipelines and between
any pipelines running in the same easement all round pipe protection must be provided
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before commencement
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7 Pilot holes to locate existing lines shall be dug by hand tools only, before allowing mechanical
equipment to operate within five (5) meters of a QP live gas, oil or NGL pipelines.
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8 Prior to exposure of any live pipeline the Contractor shall erect a suitable and substantial
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barrier to prevent any damage to QP pipelines. This is particularly important where there are
heavy vehicles in the vicinity and the possibility that removal of the bond for trenching
operations opens up an illegal vehicle crossing.
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9 When backfilling an exposed section of pipeline, naturally occurring soft dune sand shall be
used and the pipeline shall be covered and re-bedded all round with 150 mm minimum of
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sand. The remaining height of the bund will be made up of selected desert fill with particle
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size not exceeding 150mm from organic material. QP engineer shall witness the backfill
work, particularly the soft sand bedding operations.
10 When trenching between pipelines in the same easement, vehicle access between the
pipelines must be maintained.
11 The maximum length of exposed unsupported pipeline must not exceed seven (7) meters.
When it exceeds five (5) meters, a central substantial wooden support shall be installed
within a minimum 10 mm thick rubber “shoe” contacting the pipe.
12 When the bund is removed from any existing line its buried route shall be clearly indicated by
pegs and warnings.
13 Any damage to the pipe external protecting wrapping caused by the Contractor will be
repaired in strict accordance with QP procedures at the Contractor’s cost.
14 Provision of a permit-to-work by QP does not release the Contractor from obligation of

obtaining relevant permits to expose or work near utilities/facilities not under QP area of
responsibility. Examples – QGEWC, Telecom Provider etc.
14.3.5 PWA, Storm water and Groundwater
1 This subclause of the specification covers; stormwater and groundwater drainage, foul water
drainage and treated sewage effluent systems.
2 All of the material submission, inspection & testing, preparation of record sheets, preparation
of record drawings for works associated with PWA shall be carried out in accordance with the
requirements of this part of the specification.
3 Where it is necessary to make a connection to an existing water service this shall be in
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accordance with Part 14 of this Section.
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4 Works shall be in accordance with the latest PWA standard details except as modified in this
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Part. Contractors are deemed to be in possession of the latest standard details. Before
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beginning any work, the Contractor shall approach PWA and obtain a copy of their latest
specification & standard details relating to the Works.
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All work shall be carried out by a contractor or subcontractor prequalified and approved by
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PWA. Proof of such approval shall be required in writing before the start of Works on the
Site and the name of any subcontractor to be used shall be as designated.
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END OF PART
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Part 15: Road Lighting
15 ROAD LIGHTING .................................................................................................... 4

15.1 GENERAL ............................................................................................................... 4
15.1.1 Scope of Works 4
15.1.2 References 5
15.1.3 Approved Contractors 6
15.1.4 Supply of Materials 6
15.1.5 Programme of Work 7
15.1.6 Technical Requirements 7
15.2 APPROVAL OF EQUIPMENT ................................................................................. 7
15.2.1 General 7
15.3 STORAGE OF PLANT AND EQUIPMENT .............................................................. 9
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15.4 SPECIAL REQUIREMENTS .................................................................................... 9
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15.5 HIGH MAST LIGHTING ......................................................................................... 10
15.5.1 General 10
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15.5.2 High Mast Column 10
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15.5.3 High Mast Head Frame 11
15.5.4
15.5.5
High Mast Luminaire Ring
Multi Core Mast Rising Cable nt 11
12
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15.5.6 Raising and Lowering Equipment 12
15.5.7 Raising and Lowering Winch System 13
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15.5.8 Finish 14
15.5.9 High Mast Luminaires 14
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15.5.10 High Mast Distribution Equipment 15

15.5.11 Aircraft Obstruction Light 15
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15.5.12 Earthing and Lightning Protection 16

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15.5.13 High Mast Foundations Construction Requirements 16

15.5.14 High Mast General Requirements 16
15.5.15 High Mast Approval 17
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15.5.16 Maintenance Requirements 17

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15.5.17 High Mast Portable Cage for Maintenance 17

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15.5.18 High Mast Lighting Performance 18

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15.6 LIGHTING COLUMNS ........................................................................................... 18

15.6.1 General 18
15.6.2 Design Criteria for Columns 18
15.6.3 Details of Column 18
15.6.4 Details of Bracket 19
15.6.5 Doors and Base Compartments for Columns 20
15.6.6 Details of Base Flange Plate 20
15.6.7 Details of Column Foundation 21
15.6.8 Passively Safe Lighting Columns 21
15.6.9 Decorative Lighting Columns 23
15.7 LIGHTING UNITS .................................................................................................. 24
15.7.1 General 24
15.8 CONTROL GEAR .................................................................................................. 25
15.8.1 General 25
15.9 LAMPS .................................................................................................................. 25

15.9.1 General 25
15.10 LIGHTING SYSTEM FOR UNDERPASSES .......................................................... 26
15.10.1 General 26
15.10.2 Vehicular Underpass 26
15.10.3 Pedestrian Underpass 26
15.10.4 Animal Underpass 26
15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses 27
15.10.6 Underbridge or Undercrossing Lantern and Installation 28
15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps 29
15.10.8 Underpass, Underbridge or Undercrossing Isolating Box 30
15.11 LED LIGHTING UNITS .......................................................................................... 30
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15.11.1 Lighting Units 30
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15.11.2 Lighting Performance 31
15.11.3 Thermal Management 32
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15.11.4 Testing 33
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15.11.5 In Situ Temperature Measurement Test (ISTMT) 34
15.11.6
15.11.7
Control Gear
LED Lamps
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36
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15.11.8 Quality Criteria for LED Lighting 37
15.11.9 LED manufacturers data 38
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15.12 OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION ............................. 38

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15.12.1 General 38
15.12.2 Sign Gantry Lantern 39
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15.12.3 Sign Gantry Lantern Control Gear and Lamps 40

15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables 41
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15.13 PHOTO ELECTRIC CONTROL CELL ................................................................... 41

15.13.1 General 41
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15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS ........................................... 42

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15.14.1 General 42
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15.15 FEEDER PILLAR ................................................................................................... 43

15.15.1 General 43
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15.15.2 Cabinet 43
15.15.3 Components of Feeder Pillars 44
15.16 ROAD LIGHTING CABLES ................................................................................... 45
15.16.1 Underground Cables 45
15.16.2 Packing of Cables 45
15.16.3 Insulated PVC Sheathed Circular High Temperature (85°C) 46
15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES .................................. 46
15.17.1 General 46
15.17.2 Material & Quality 46
15.18 MARKER POSTS .................................................................................................. 46
15.18.1 General 46
15.19 EARTHING ............................................................................................................ 46

15.19.1 General 46
15.20 INSTALLATION ..................................................................................................... 47
15.20.2 Temporary Lighting 48
15.20.3 Removal of Existing Columns 48
15.20.4 Detailed Drawing for RCC foundation 49
15.20.5 Road lighting Column/Lantern Installation 49
15.20.6 Road lighting Feeder Pillar Installation 50
15.20.7 Road lighting Cable Installation 50
15.20.8 Road Crossing Ducts 51
15.20.9 Backfilling and Re-instatement 52
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15.20.10 Road lighting Cable Terminations and Testing 52
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15.20.11 Electrical Power Supply 53
15.21 TESTING AND COMMISSIONING ON SITE ......................................................... 53
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15.21.1 General 53
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15.21.2 Electrical Tests 53
15.21.3 Photometric Performance Testing
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15.22 RECORD DRAWINGS .......................................................................................... 55
15.22.1 General 55
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15 ROAD LIGHTING
15.1 GENERAL
15.1.1 Scope of Works
1 Work related to the road lighting installation provided for in this specification shall include the
supply, installation, testing, commissioning and putting into satisfactory operation any or all of
the following systems as required by the project drawings.
(a) Road lighting (L.V) cables and terminations.

(b) Road lighting Feeder Pillar and internal associated control equipment including
photocell control.
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(c) Road lighting column/lantern assemblies.
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(d) High mast lighting mast/lantern assemblies.
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(e) Roadway Lighting System control, adaptive, smart or remotely managed
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(f) Lighting network earthing, including electrical grounding.
(g) nt
Installation testing including lighting performance verification.
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(h) Provision of equipment technical and maintenance data.
2 The Contractor shall provide the shop drawings and supporting calculations required by the
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specification, as well as the provision of all required supporting technical literature and
samples in connection with the approval of proposed equipment.
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3 The equipment supplied shall include all necessary items for a complete installation
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according to the specification requirements in order to provide for satisfactory operation, not
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withstanding errors and omission. The equipment listed in the Contract documents are,
therefore, indicative and not limitative.
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4 On satisfactory completion and commissioning of the lighting installation the Contractor shall
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be responsible for the maintenance of the whole system for a period of 400 days. This will
include for the free replacement of any component or lamp that fails during that period of
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time. In addition, the Contractor shall be responsible for the rectification of any fault that
occurs within the cabling network. As part of this rectification work no cable joints will be
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permitted.
5 All of the works associated with the road lighting installation shall be carried out in
accordance with the "Regulations for the Lighting of Roads for Motorised Traffic" and the
latest specifications issued by the PWA including The Qatar General Electricity & Water
Corporation “KAHRAMAA” Regulations for the Installation of Electrical Wiring, Electrical
Equipment.
6 The Contractor is deemed to be in possession of these regulations and the latest

specifications.
7 The luminaire shall be suitable for connection to the low voltage single phase supply of the
main network grid in The State of Qatar.
15.1.2 References
ANSI/IESNA RP-008 ..Roadway Lighting
BS HD 60269-2 ..........Low Voltage Fuses. Supplementary requirements for fuses by
authorized persons (fuses mainly for for industrial application)
BS 302........................Specification for higher breaking load ropes
BS 791........................Solid-stem calorimeter thermometers
BS 1011......................Process of arc welding of carbon and carbon manganese steels
BS 2484......................Straight concrete clayware cable covers
BS 4343......................Plugs, socket-outlets and couplers for industrial purposes
BS 4360......................Weldable structural steels
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BS 4533......................Luminaires
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BS 4800...................Colour chart
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BS 5467......................Cables with thermosetting insulation for electricity supply for rated
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voltages of up to and including 600/1000 V and up to and including
1900/3300 V
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BS 5486......................Low voltage switch gear and control gear assemblies
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BS 5489......................Road lighting
BS 5649......................Lighting columns
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BS 5972......................Photoelectric Control Units for Road Lighting

BS 6121......................Mechanical Cable Glands for Elastomer and Plastic Insulated Cables
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BS 6141......................PVC insulated PVC sheathed circular flexible cables

BS 6346......................PVC-insulated Cables for electricity Supply
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BS 6360......................High conductivity stranded copper shaped conductor with XLPE

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insulation
BS 6622......................Cables with extruded cross-linked polyethylene or ethylene propylene
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rubber insulation for rated voltages from 3800 / 6600 V up to 19 000 /

33 000 V
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BS 6746......................Extruded black PVC over sheath

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BS 6977......................Specification for insulated flexible cables for lifts and other flexible
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connections
BS 7430......................Code of practice for earthing
BS 7671......................Requirements for electrical installations
BS EN 40.................Lighting Columns
BS EN 295..................Vitrified clay pipes, fittings and pipe joints for drains and sewers
BS EN 1011................Welding
BS EN ISO 1461 ........Hot dip galvanized coatings on iron and steel articles
BS EN1559-1 ............Founding. Technical conditions of delivery. General.
BS EN1559-4 ............Founding. Technical conditions of delivery. Additional requirements for
aluminium alloy castings.
BS EN1676.................Aluminium and aluminium alloys. Alloyed ingots for remelting
BS EN 10137..............Plates and wide flats made of high yield strength structural steels
BS EN 10210..............Hot-finished hollow sections

BS EN 12767...........Passive Safety of Support Structures
BS EN 60529..............Degrees of protection provided by enclosures
BS EN 60898..............Miniature and moulded case circuit breakers
BS EN 60947-3 ..........Air-break switches, air-break disconnectors, air-break switch
disconnectors and fuse combination units for voltages up to and
including 1000 V ac and 1200 V dc.
BS EN 62305..............Protection against the lighting
IEC 60598 ..................Luminaires for roadway lighting
CIE 126-1997 ............Guidelines for minimizing sky glow.
EN62262:2002 ..........(IEC62262:2002) Degrees of protection provided by enclosures for
electrical equipment against external mechanical impacts.
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The Qatar General Electricity & Water Corporation “KAHRAMAA” Regulations for the
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Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment.
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The Qatar Highway Design Manual (QHDM). Current edition.
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WEEE Directive (2002/96/EC).
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RoHS Directive (2002/95/EC).
Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety

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Institution of Lighting Engineers (ILE), Technical Report No 7 ‘High Masts for Lighting and
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CCTV’
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ISO 9001, Quality Management Systems

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Institution of Electrical Engineers (IEE), Wiring Regulations

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State of Qatar, Qatar Wiring Regulations

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American Association of State Highway and Transportation Officials (AASHTO) “Roadside

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Design Guide”
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15.1.3 Approved Contractors
1 All road lighting works shall be carried out by a contractor or sub-contractor approved by the
PWA. Proof of such approval shall be required in writing prior to the works commencing on
site and the name of any sub-contractor to be engaged shall be entered in appropriate forms
during tender submittal.
15.1.4 Supply of Materials
1 The Contractor shall supply all the materials required to carry out the Works as specified in
the Contract Documents and Drawings. No materials will be supplied by the Owner or the
PWA.
15.1.5 Programme of Work
1 The Contractor is responsible, with the agreement of the Engineer, for all liaisons with the
respective department within PWA, in respect of programming the installation and
commissioning of the complete road lighting system. In addition to the Engineer, he shall also
ensure that relevant departments within the PWA are at all times kept informed of the current
progress of the road lighting works on site and that his approved sub-contractor programme
works are in the specified sequence in accordance with the overall approved Works
programme.
15.1.6 Technical Requirements
1 All works carried out on the installation shall be in accordance with the requirements of these
specifications so that their true meaning and intent are fulfilled. Minor deviations from the
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drawings may be made to accomplish this but no change shall be made without written
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approval of the Engineer and in consultation with the relevant departments within the PWA.
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2 In addition to all the regulations, codes of practice and standards referred to within this
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specification, all the lighting and associated electrical works shall comply with the current
Qatar wiring regulations and the requirements of PWA.
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Where applicable, any associated work involving other authorities in the State of Qatar their
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relevant standards and specifications, as issued by them, shall be complied with.
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4 All equipment and materials supplied for the project shall be manufactured in strict
compliance with the latest standard of BS, IEC, EN their equivalent AASHTO or other
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standards and regulations specifically referred to in this specification. Here in after they are
referred to as the “Standards”.
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5 Acceptance tests shall conform to those referred to in the above mentioned “Standards”.
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15.2 APPROVAL OF EQUIPMENT

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15.2.1 General
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1 All materials shall be approved by the Engineer. The Contractor shall be responsible to
ensure that, where applicable, for nominated items of equipment only the type and
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manufacturer approved by the PWA, as detailed in their List of Approved Manufacturers are
submitted for incorporation into the works. In addition, written approval must be obtained
from the PWA, prior to ordering. Contractors shall note that only products with a proven
record of performance, efficiency and long life will be considered for approval.
2 The Contractor shall not order any equipment for the incorporation into the Works before
receipt of formal approval in writing. The approval procedure shall be as follows:
(a) The Contractor shall submit four copies of his equipment proposals to the Engineer.
This submission shall be comprehensive and clearly state any manufacturer’s
deviations from the specification. Manufacturer’s literature associated with the
submission shall be originals and not photocopies. Specific reference to the
compliance of certain specification requirements shall be identified.
(b) The Engineer shall review this submission. The Engineer’s approval shall be as
follows.
(i) With the Engineer’s comments and recommendations attached, a copy of the
submission shall be forwarded to the departments concerned within the PWA, to
obtain their approval.
(ii) Where minor deviations exist from the specifications but do not affect the
performance of the equipment or installation the Engineer’s recommendations to
accept such deviations, his approval together with a copy of the submission
shall be forwarded to the departments concerned within the PWA, to obtain their
approval.
(iii) Approval shall be transmitted to the Contractor in writing once the approval of
the relevant departments within the PWA, has been given.
3 All submissions shall give clear, unambiguous details and performance data of the
equipment proposed, together with all supporting calculations where necessary. Clear
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catalogue identification references shall be provided. Documents shall be in English.
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4 The Engineer reserves the right to direct the Contractor to provide equipment of a make and
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type that is essential to achieve the Contract design criteria.
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5 Approval of samples by the Engineer in consultation with the relevant departments within the
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PWA, does not in any way relieve the Contractor of his contractual obligation in respect of the
suitability of the equipment or their final performance once installed, and the co-ordination
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with all the elements of the lighting works into a fully operational installation.
6 After receipt of equipment the Contractor shall arrange for them to be examined and
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approved by the Engineer’s Representative in consultation with the relevant department

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within the PWA, prior to installation.
7 Column and Mast Fabrication Requirements

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In paved or walkways areas Enclosure plate is required. The Enclosure plate shall be cast
Aluminium or Galvanized steel, comprising two removal halves per base with size matching
the base plate. It shall be painted to match pole finish. Provided with backup plate to one
halve of Enclosure Plate and with tapped holes to accept stainless steel screws countersunk
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into other half of Enclosure Plate.

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8 Specific Requirements for Columns

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The gap between base plate and top of foundation shall be grouted. Means of discharging
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any accumulated moisture shall be provided at the pole base and provision shall be made for
adequate drainage.
9 Testing and Factory Visits
The contractor shall facilitate authorised Engineer representatives, and/or their appointed
representative, to examine the test and manufacturing facilities and witness
manufacturing processes and sample testing related to the luminaire and associated
components submitted for evaluation, at no cost to Ashghal or their appointed
representative.
10 Saving Energy Lamp’s Luminaire specification data sheet arrangement or each model of
luminaire the manufacturer shall produce a data sheet providing a detailed and
comprehensive description of the luminaires characteristics and component parts. The data
sheet will contain adequate information for the reader to select and specify a particular model
from the luminaire range. This will include;
(a) luminaire diagram external dimensions, weight and windage

(b) optical arrangement (lens and reflectors types and settings)
(c) driver type (drive current, system power consumption)
(d) luminaire output (lm)
(e) luminaire efficiency (lm/W)
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(f) glare rating
(g) control and switching options (photocell, programmed stand alone, CMS, etc.)
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15.3 STORAGE OF PLANT AND EQUIPMENT
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All plant and equipment shall be stored off the ground under weatherproof cover ready for
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incorporation in the works. All electrical apparatus shall be examined and cleaned before
installation. All open conduit ends shall be fitted with plastic caps or suitable protective
covering to prevent the ingress of foreign matter. All drums with cables shall be protected
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from direct sunlight.

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15.4 SPECIAL REQUIREMENTS

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1 All notices from the Contractor shall be in writing and delivered by hand.
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2 The Contractor shall consult the Engineer not less than one month before it is proposed to
commence work to ascertain whether any underground installations will be affected by the
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proposed work, in which event the Contractor shall make all necessary arrangements with
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the Engineer to safeguard the installation. It will be the Contractors responsibility to liaise with
the utility authorities and to arrange for all road opening notices
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3 The Contractor shall give at least one week's notice in writing to the utility authority’s
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Engineer of the dates upon which it is intended to operate plant or equipment or carry out any
work for which permission has been given in writing by the utility authority’s Engineer. Such
operations of work shall only be carried out in the presence of the utility authority’s Engineer
unless notice shall have been in writing from the utility authority’s Engineer that they do not
require to be present.
4 The utility authorities may require work to be executed on their installation during the period
of the Contract. The Contractor shall afford all facilities to the utility authority’s contractors or
workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
the utility authorities and his own activities and when necessary shall amend his programme
of working to suit all requirements of the utility authorities in connection with their diversion
work and shall keep the Engineer informed in writing of all arrangements made.
5 The Contractor shall locate and mark with suitable posts all the utility authority’s underground
installations that are within the area of the Works and shall ensure that such markers are
maintained in their correct positions at all times. The Contractor shall advise the utility
authority’s agent of any installation not found where shown on the Drawings, or found but not
shown or found damaged or subsequently damaged.
15.5 HIGH MAST LIGHTING
15.5.1 General
1 This work shall consist of the supply, installation upon prepared foundations, connections,
commissioning and putting into satisfactory service the high masts complete with the
operating mechanisms, luminaire support ring or bracket, luminaries, control gear, wiring and
distribution equipment.
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2 The mast luminaire support ring shall be designed to provide for the appropriate distribution
of lighting either in one direction or in many directions thus making it possible to concentrate
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the required number of luminaires on any zone and fix them rigidly in any direction desired.
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Prepared foundations are specified in other sections of this specification.
15.5.2 High Mast Column nt

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1 The high mast column shall be of the height specified on the Drawings, hot dipped
galvanized to BS EN ISO 1461 or BS 791 of multi-sided cross-section with a continuous
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taper made of formed sheet steel in accordance with BS 4360 grade 43C and electrically
welded. They shall be delivered to the site in manageable sections of not greater than 12
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metres and be joined by means of pressure over-lapping or slip-joints, which shall have a
minimum length of 1.5 times diameter of the joint. Site welding will not be allowed.
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2 The walls of the masts shall have a minimum thickness of 6mm for the base section, 5mm
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for the central section and 4mm for the top section. The steel used shall have tensile strength
between 490 and 630 MN/sqm and minimum yield strength of 355 MN/sqm.
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3 The mast cross-sections shall be so designed that once installed and fully equipped, it shall
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have safety factors in accordance with Technical Report No. 7 of the Institute of Lighting
Engineers – London and shall be capable of withstanding wind load resulted from the wind
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speed provided in Section 1 Part 1 Clause 1.5.2, and blowing in the most unfavourable
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direction at a height of ten meters above ground level. Appropriate reinforcement shall be
provided where necessary to increase the strength. Its behaviour under wind induced
oscillation shall be such that it shall not fail due to fatigue and the design should ensure that
these oscillations be damped to a minimum of zero.
4 The maximum deflection at the top of the mast shall not exceed 2.5% of the mast height at
the minimum wind speed provided in Section 1 Part 1 Clause 1.5.2.
5 A steel flange plate of adequate thickness and free from laminations shall be welded above
and below the base of the mast developing fully the strength of the section. In addition
supplementary gussets shall be provided between bolt holes if deemed necessary.
6 An access door shall be provided in the base of the mast of adequate dimensions to permit
clear access to the back plate installed for the mounting of the circuit breaker assembly and
junction box, winch, etc. The backboard shall be made of steel or other non-hydroscopic
material. The door shall be completely weatherproof fitted with a hidden hinge and a heavy
duty lock. The door area shall have appropriate reinforcement.
7 A stainless steel earthing 12mm diameter bolt shall be welded inside the mast near the
access door and shall be complete with stainless steel washers and nuts.
15.5.3 High Mast Head Frame
1 The head frame shall be hot-dipped galvanized steel attached to the mast by means of a
steel slip-fitter and secured by at least four stainless steel set screws. It shall be composed of
spun aluminium or other approved weatherproof cover, housing the required number of steel
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cable sheaves and associated accessories for the operation and powering of the luminaire
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ring.
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15.5.4 High Mast Luminaire Ring
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1 The high mast luminaire support ring or carriage shall be constructed of hot dipped
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galvanized steel channel fitted with the appropriate number of luminaires, lamp gear
mounting brackets, wiring chamber and mounting plate. It shall be in two halves joined by
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bolted flanges to permit removal from the erected mast. The luminaire shall be mounted on
the luminaire rings by means of either a specially designed bracket allowing it to be swiveled
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in any desired direction or rigid bracket arm assembly. It shall be possible to lock each
luminaire firmly in position, thus preventing any rotation or falling while moving the luminaire
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ring.
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2 The carriage assembly shall be arranged to locate firmly against stops when in the secure
position and these shall be of adequate strength to ensure that they cannot be damaged by
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over winding of the winch.
3 A shaped protective aesthetic canopy, designed to give a coordinated appearance of head

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frame with the luminaire ring, shall cover the head frame.
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4 For masts fitted with a mobile luminaire ring, rollers with a centering mechanism shall be
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provided to ensure a perfect alignment of the luminaire ring both axially and in azimuth, while
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ascending or descending the mast. Rollers shall be made of water resistant non-marking
composition material with oil-impregnated bronze brushings. All shafts and washers shall be
stainless steel.
5 A weatherproof wiring chamber or terminal box shall be provided constructed from a

corrosion resistant material or aluminium alloy and installed on the luminaire ring. It shall be
equipped with the high temperature shrouded terminal blocks and neutral bar or block and
shall include facilities on the luminaire ring to allow testing of luminaires while in the lowered
position. The wiring chamber shall be fitted with an earthing stud accessible from inside and
out for earthing connections. The housing shall be completely weatherproof.
6 The cables installed in the luminaire ring connecting each luminaire to the wiring chamber
shall be factory pre-wired avoiding the need for field wiring, and shall have single core copper
conductors with neoprene or cross-linked polythene or approved equivalent insulation and
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sheath. Cables shall be either single core or 3 core 2.5mm with copper conductors and
colour coding of the different phases being in conformity with the relevant cabling standards.
7 Cables from the terminal box shall run in PVC duct or metal duct fixed to or within the
luminaire carriage to each luminaire from the wiring chamber.
15.5.5 Multi Core Mast Rising Cable
1 The cable connecting the MCCB assembly at the base of the mast to the wiring chamber on
the luminaire ring, shall be a flexible multicore copper cable with conductors and neoprene or
approved equivalent high temperature resistant insulation and sheath in accordance with BS
6977.
2 The colour coding of the different phases of the cable shall conform to the relevant cable
standards. Each luminaire shall have its own neutral conductor connected to the neutral bar
or block.
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3 The mast cable shall consist of a circular multi core cable to BS 6977 600/1000V grade.
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Each conductor core shall be insulated with ethylene propylene rubber (EPR) and the
complete core is sheathed with heavy duty polychloroprene (PCP).
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4 A multicore electrical power cable shall be provided terminating in the base compartment with
a special multi-pin plug and socket coupler fitted with a guard, and at mast head connected
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to the wiring chamber fixed to the luminaire ring. It shall be suitable for the bending, flexible
and load carrying stresses involved.
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5 The cable shall be fitted with a correctly rated multi pin weatherproof plug and socket within
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the base compartment of the mast which will enable the cable to be disconnected before
lowering the luminaire carriage. The socket must be connected to the supply side of the
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circuit and may either be free cable coming from the fuse box or be fixed to the fuse box in
the base compartment.
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6 The wiring shall be such that the plug and socket can be isolated before disconnecting.
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7 The cable shall be suitably restrained to prevent its own weight from causing the terminal box
to energise the lanterns.
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15.5.6 Raising and Lowering Equipment

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1 The pulleys located within the headframe shall be of non- corrosive cast aluminium alloy
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material grooved to exactly suit the steel rope and cable diameters, and fitted with stainless
steel shafts. The pulleys shall be housed in a chassis integral with a sleeve, which slopes
over the top of the mast and is secured axially and in azimuth. The complete chassis
assembly shall be hot dipped galvanized. A guard is to be provided for the separation of the
wire rope and power cable before entering in the pulley and the locating of the steel wire rope
and power cables in their groves when operating either loaded or slack. An arrangement
shall be provided to ensure that the electric and steel cables are separated before passing
over their respective pulleys, and close fitting guides shall ensure that the cables cannot
disengage the pulley during operations.
2 The luminaire carriage shall have the provision made on it for supporting and gripping the
weight of the supply cable without damage of the cable sheath.
3 The luminaire ring shall be supported by 3 steel ropes coupled to 2 steel ropes and
suspended from the double drum winch by means of a manufactured steel coupling unit. A
divider bar shall ensure the separation of the steel ropes during raising and lowering.
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8 An MCCB providing overload protection shall be incorporated to stop the ring when the effort
required by the winch becomes superior to the nominal load.
9 The winch shall be fitted with suitable equipment to allow the winch to stop in a safe manner,
without damage to the mast finish, in the event of a supply failure to the power tool. The
winding mechanism should then be capable of being operated by hand.
10 Each winch supplied shall be uniquely identified. In addition it shall have its own individual
test certificate recording the safe working load. Lubrication details shall also be permanently
recorded on its housing for future maintenance purposes.
15.5.8 Finish
1 All welds shall be smooth with the splatter removed and the interior and exterior surface of
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the mast and ring shall be cleaned by pickling or blasting and shall be free of any grease.
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2 All components shall be hot dipped galvanized by total immersion in a bath of molten zinc
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after completion of the fabrication. No further levelling up, finishing or modifications shall be
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carried out after completion of the galvanizing process. The minimum thickness of zinc
coating shall be 450 gm/sqm on the inside and outside surfaces of the mast and ring. The
galvanizing shall conform to BS EN ISO 1461.
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3 Any damage to the galvanizing shall be rectified during erection by wire brushing the affected
area and treating with an approved zinc restorative. Sufficient materials shall be applied to
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provide a zinc coating at least equal in thickness to the galvanized layer.

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4 If required by the Engineer the underside of the flange plate and internal surface of the mast
to a height of 0.5m shall be given a coat of heavy duty bitumen paint prior to erection.
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15.5.9 High Mast Luminaires

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1 The high mast luminaire shall have a ‘cut off’ distribution. It shall be of the side entry
mounting type, with toughen a flat glass protector and integral control gear suitable for the
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operation of either a 400W with lumens per watt rating of no less than 48,000, or 600W with
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lumens per watt rating of no less than 88,000, 220-240V, 50Hz. High Pressure Sodium
tubular lamp of E-40 base, as defined for the contract.
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2 The luminaires to be adopted shall be high performance street lighting lanterns currently
used for conventional roadway lighting routes to BS 5489 or equivalent suitable for use at a
mounting height of 25 or 30 metre. It shall comply with IEC 60598 or other approved
equivalent norms. The body shall be made of die-cast aluminium and shall be divided into
two separate compartments.
3 The first compartment of the luminaire shall house the optical system with polished and
anodized pressure aluminium reflector. The second compartment shall contain the electrical
accessories (control gear) cable feed terminals and side entry mounting socket. This
separation shall protect the electrical accessories from the direct radiant heat emitted by the
lamp. The optical compartment shall be protected by a toughened flat glass protector and
shall be dust and watertight to a protection rating of IP65.
4 The access to the optical compartment shall be by tilting the protector frame around the
hinge without tools. A heat resistant gasket fitted on the frame shall ensure the tightness of
the optical compartment. The accessories such as ballast, ignitor, and capacitor shall be re-
wired and pre-assembled by a metallic plate that is mounted and fixed into the rear
compartment. Special care shall be taken to allow easy maintenance and quick replacement
of the accessories and to minimise the risk of falling.
5 The cable feed terminal and the earth-screw shall be fixed to the metallic compartment, a
cable holder shall be mounted near the terminals. The side entry mounting sockets should
accept a 125 mm. long spigot and 50 mm diameter OR adjustable from 42 to 60 mm dia.
Exterior side of both compartments should be with grey colour in finish.
15.5.10 High Mast Distribution Equipment
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1 The high mast base compartment shall be fitted with a power control and distribution
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assembly installed in a pre-wired weatherproof box opposite the access door inside the base
of the mast.
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2 The assembly shall consist of a surface mounted sheet steel weatherproof box with a cover
enclosing:
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One 3-pole main 60Amp MCCB together with a neutral link for luminaire circuits. The
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ratings of the MCCB shall be in accordance with the QGEWC regulations and suitable
to the connected load and cable.
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(b) One single pole 20 Amp MCB with neutral link for each luminaire circuit of a suitable
current rating.
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(c) One-pole MCCB with neutral link connected to the incoming supply and serving a 16A-
250 V DIN socket outlet complete with 3-pin plug to suit the raising and lowering
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mechanism.
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(d) A multi-pin plug and socket outlet with guard fitted with cable outlet for connection to
the multi-core electric power cable provided from the MCCB to the luminaire ring wiring
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chamber.
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3 The MCCB’s shall be de-rated and calibrated to provide over-current and short circuit
protection when used in an ambient temperature of 50oC and shall have the required
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breaking capacity. The incoming side of the triple pole MCCB with the neutral links shall be
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fitted with a 4-way, line-tap type terminal block, with each terminal capable of accepting 2 x
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35mm copper conductors.
4 The multi-pin coupler for supply to the portable raising and lowering power tool shall be
connected to the MCCB via a flexible connection to ensure accessibility.
5 Where an high mast assembly supplies a ground sign lighting unit or equivalent it shall be
equipped with an additional 15 Amps circuit breaker to supply the sign lighting installation.
The circuit breaker shall be installed inside the mast distribution box.
15.5.11 Aircraft Obstruction Light
1 Where required by Civil Aviation Authorities, two red luminaires within cast aluminium bodies
shall be fitted at the top of each high mast attached to the movable luminaire ring with a
purpose made bracket and arranged to project through the canopy.
2 The luminaires shall be provided with a change over relay such that, in the event of lamp
failure, the second lamp is automatically connected. Lamps shall be GLS Rough Service 100
watt suitable for an E.S. (E27) lampholder.
3 The obstruction lights shall be wired on a separate circuit protected by a separate SP & N
circuit breaker with terminals to accept separate incoming cables.
15.5.12 Earthing and Lightning Protection
1 All masts shall be provided with a separate system for earthing as a protection against
lightning. This shall comply with BS EN 62305.
2 High masts shall be equipped with an air terminal of the correct height to provide the required
zone of protection for the mast head frames and fixtures. The air terminal shall be bonded to
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the mast to ensure the discharge is dissipated via the earth ground terminal without damage
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to the steel winch ropes or electrical cables.
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3 Separate earthing shall be provided for each item of control equipment within the mast
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assembly and connected to a central earthing point.
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A 12mm diameter stainless steel or brass stud with nuts and washers in the base
compartment connected to the main body of the mast structure shall be provided.
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15.5.13 High Mast Foundations Construction Requirements
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1 High masts shall be installed on concrete bases as detailed on the Drawings. The foundation
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design and construction shall be as based on the high mast manufacturers recommendations
according to the ground and climatic conditions that exist at the site location. The erection of
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high masts and the assembly of the luminaire, head frame with raising and lowering gear
shall be carried out strictly in accordance with the manufacturers’ instructions. The Contractor
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shall before commencement of the construction work confirm by means of structural

calculations that the foundations proposed are suitable for use with the high mast installation
he proposes to install. Holding down bolts and plumb adjustment nuts, washers, locknuts or
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nyloc nuts shall be galvanized steel or cadmium plated.

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2 The holding down bolt/nuts complete with the anchor plate for casting into the foundation
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shall be provided by the high mast manufacturer together with a mild steel anchor bolt
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template with tube holes to ensure correct vertical and precision made horizontal bolt
alignment.
3 The anchor bolts shall be of guaranteed performance high tensile steel.
4 All buried external surface of the high mast foundation shall be protected by brush painted
tanking membrane and hard board protection.
15.5.14 High Mast General Requirements
1 Final setting and adjustment of the luminaires shall only be carried out after all the masts
along a route, junction or interchange are complete and operational.
2 Each high mast metal work shall be bonded to a separate earth rod as indicated on the
Drawings and also to the separate earthing cable connected to the distribution system earth
bar.
3 The high mast shall be of specified height carrying luminaires as indicated on the Drawings.
Each luminaire shall be fitted with the specific lamp or lamps arranged to be separately
oriented to give the correct illumination at designated locations along the road surfaces.
15.5.15 High Mast Approval
1 For the approval of the Engineer before manufacturing commences the Contractor shall
submit detailed calculations and supporting data to show that the mast meets the design
criteria detailed and shall include the following information:
(a) The deflection at the top of the mast at the designed wind speed.
(b) The neutral frequency of the mast.
(c) The critical wind speed for resonance.
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(d) The damping characteristics of the mast.
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(e) The steel stressed under resonant conditions.
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(f) The acceleration at the top of the mast under resonant conditions.
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(g) Welding procedure.
(h)
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Procedure to ensuring that the flange plate is not laminated.
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(i) Details of the joints between the mast sections and between the bottom section and
the flange.
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(j) Details of the base compartment with the method of reinforcement at the door area
and means adopted for making the door weather and tamperproof.
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15.5.16 Maintenance Requirements

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1 The following items must be provided for the Engineer at the time of the commissioning of
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any high mast assembly:
(a) Power tools – 1 No.

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(b) ‘L’ hooks – 6 No.

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(c) Operating handles – 2 No.

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(d) Foundation Bolt/Nut and Head frame Nut/Bolt Spanners – 2 No. Sets.
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15.5.17 High Mast Portable Cage for Maintenance
1 The high mast system shall incorporate a mobile luminaire ring such that it is suitable for
utilising a purpose made portable cage for maintenance purposes.
2 The cage shall be obtained from the high mast supplier and shall be capable of carrying two
persons plus servicing equipment.
3 A safety system shall be provided for use with the cage according to the manufacturer’s
recommendations. One safety cage per project shall be allowed within the pricing structure
offered by the Contractor for the future use of the Engineer.
15.5.18 High Mast Lighting Performance
1 The Contractor must provide guaranteed lighting performance data as part of his technical
submission to confirm the minimum light values that will be maintained at each location and
where specifically identified by the Engineer or representatives from the relevant departments
within the PWA.
2 The minimum light levels that must be obtained shall be:

Horizontal illumination 30 LUX
Diversity Factor (Ave/Min) 4:1
15.6 LIGHTING COLUMNS
15.6.1 General
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1 All columns and brackets shall be produced by ISO 9001 certificated lighting column
manufacturers registered and certified for the manufacture, supply and certification of lighting
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columns under their quality assessment schedule.
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2 All columns of the same mounting height and with the same arrangement shall be identical in
construction. nt
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3 Road lighting columns shall be hot dip galvanized steel, octagonal, multisided, tubular and
stepped shape, of height as detailed in the Contract specification and drawings, complete
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with bracket of outreach, number of arms and of shape all again as detailed in the Contract
specification or on the drawings.
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15.6.2 Design Criteria for Columns

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1 For all columns and masts the stress and deflection calculations shall be based on the
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maximum bracket and luminaire projection, on the bracket arm, with projected area, length
and weight as designated.
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2 In still air conditions, loaded with the designated luminaire positioned in any of the variable
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locations, there shall be no appreciable deflection of the column.

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3 The maximum permissible deflection in the column or mast shall be 1° in any 1m length with
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4 Columns must be designed to withstand the wind force.
5 The "K" factor for columns over 8 m in height shall be 2.2.
6 Columns shall be designed to support lanterns with the data given by the Engineer.
15.6.3 Details of Column
1 The column shall be made from hollow sections to BS EN 10210 in steel to BS 7613 grade
43C or any approved equivalent norms. The hollow sections shall have a minimum tensile
strength of 430 N/mm² and minimum yield strength of 255N/mm².
2 Columns shall be in one piece tubular (round), stepped shape or multi-sided sheet steel and
be of the flanged (bolted) type.
3 Columns should be designed in accordance with BS 5649 in steel and finished with hot dip
galvanized internally and externally with no other treatment in accordance with BS EN ISO
1461 or equivalent.
4 The jointing of the column shall be carried out by reducing the diameter of the base section to
form an interface fit with the bore of the upper section. The upper section shall be heated and
pushed over the lower section. The thermal shrinkage shall ensure a complete bond over the
full area of the joint and develop the full strength of column at the transition. The final
operation is to weld the lower section to the upper section and dress the weld to a smooth
profile. Welding shall be carried out in accordance with BS 1011.
5 Strengthening shall be provided at the door opening. Care shall be taken to ensure that
rounded edges are provided at the corners of the door opening to avoid stress
concentrations.
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6 The top of the column should be designed and provided as suitable to fix the bracket arm
collar with the top of the column as shown in the Contract drawings.
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7 All dimensions for the column shall be in accordance with the latest requirements of the
PWA, and, if applicable, as detailed on the drawings. Modifications to suit the particular
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foundation/support details proposed by the manufacturer shall be submitted to the Engineer
for approval prior to incorporation.
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15.6.4 Details of Bracket
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1 Brackets shall be formed of hollow sections to BS EN 10210 in steel to BS EN 10137 Grade

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43C or equivalent.
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2 The column bracket arms and spigots shall be so designed that when assembled with the
shaft the design altitude of the arm and projection shall be as detailed in the contract
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requirements.
3 Welding on bracket arm shall be carried out in accordance with BS EN 1011.

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4 Brackets shall be hot dip galvanized to BS EN ISO 1461 or equivalent. The bracket arm shall
be so designed that when assembled on the column shaft the altitude of the arm and spigot
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shall be 5° above the horizontal unless otherwise stated in the Contract documents.
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5 Length of the luminaire fixing spigot unless otherwise designated to suit the luminaire shall be
150mm, outside diameter of spigot shall be 42mm, thickness shall, be 4mm.
6 The securing arrangement of the bracket arm to the column shall be positive so as to ensure
that the arm does not rotate and shall be such that the bracket can be fixed in any of four 90
degree positions in relation to the column door opening. 8 No. socket set screws of size M10
x 16mm or approved equivalent arrangement shall fix the bracket onto the columns using
stainless steel screws.
7 The luminaire shall be securely fixed to the mounting post or bracket by means of a
clamping system that will prevent movement in high winds. All component parts shall be
manufactured from non-corrosive materials.
15.6.5 Doors and Base Compartments for Columns
1 Each column and mast shaft shall have a base compartment large enough to offer easy
access to the equipment therein.
2 The weatherproof door provided for each opening which shall be interchangeable between
columns of the same mounting height. To avoid accidental spillage of water from irrigation of
flooding the bottom of the door shall be at least 0.5m above the top of the foundation.
3 A stainless steel durable non-corroding tamper-proof lock device shall be provided of the
triangular headed screw type, unless designated otherwise. Where applicable, door lock
recess shall incorporate adequate drainage such that they are unlikely to become blocked
and so form a water trap.
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4 Door openings are to be kept to the minimum size consistent with the cable termination units
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and any control gear.
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5 When installing lighting columns on a single carriageway the column doors shall be located at
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90° to the kerb line and in such a location that the maintenance operative faces the oncoming
traffic and to ensure that the door can be opened at all times without encroaching onto the
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highway. In the case of installing lighting columns within the central median the column door
shall be located perpendicular to the road such that the maintenance operative will be facing
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across the line of the carriageway. The door openings shall be free from any irregularities
and burrs.
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6 Keys are to be provided with the first consignment of columns at the rate of 10 % of the total
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number of columns.
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7 A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely

fixed in each compartment and shall be of sufficient size to accommodate the cable
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termination unit.
8 Single purpose earth terminals shall be provided in a readily accessible position, preferably
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on the left hand side of the opening and on the column door.
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9 The baseboard shall be fixed using brass or stainless steel nut and bolt arrangement.
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10 All door lock hinges and catches shall be greased before handover.
15.6.6 Details of Base Flange Plate
1 The base flange plate shall be manufactured from steel plate that is free from laminations.
The main shaft of the pole shall penetrate the full depth of the base plate and is to be welded
above and below using a semi automatic MIG shielded arc process. Additional strength shall
be provided by gusset plates located between hole positions.
2 4 No. slots allowing for adjustment shall be provided in the flange plate of suitable size so as
to accommodate the foundation bolt specified to fix the column on the RCC foundation.
15.6.7 Details of Column Foundation
1 The manufacturer of the road lighting column shall submit the dimensions and specification
of his proposed foundation including the steel reinforcement details to the Engineer for
approval.
2 The foundation shall accommodate 4 No. holding down bolts of size 25mm x 800mm for
columns up to 10 metres high and 33mm x 900mm for 12 and 16 metres high columns,
supplied with two nuts and two washers to each bolt.
3 Foundations shall be constructed such that they avoid being a hazard to pedestrians
and bicyclists on footways and shared use paths. The top surface of concrete column
foundations on pathways shall not be higher than ground level, and shall not be higher than
50 mm above ground level on all other surfaces.
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15.6.8 Passively Safe Lighting Columns
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1 Design Criteria
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(a) All Passively Safe lighting Columns shall comply with BS EN 12767 – Passive safety of
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support structures for road equipment – requirements, classification and test methods,
2007 or all road lighting columns within the clear zone (as AASHTO Roadside Design
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Guide Table 3.1 or Chapter 10 Roadside Safety Urban or Restricted Environments)
shall be protected by an approved barrier system.
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(b) Each Passively Safe Lighting Column shall be anodized aluminium or galvanized steel
as specified in the Contract Documents. Design of aluminium columns shall
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comply with BS EN 40, Part 6 and its incorporated references. Design of steel
columns shall comply with BS EN 40, Part 5 and its incorporated references.
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(c) In addition to section 15.6.2-1 the passively safe columns in still air conditions, loaded
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with the designated luminaire positioned in any of the variable locations, there shall be
no appreciable deflection of the column. The maximum permissible deflection for
passively safe poles shall not exceed 4% of the total length of the pole when furnished
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with bracket arm, and 2% of the total length of pole with no bracket arm. Columns
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must be designed to withstand a base wind speed of 30 metres/second. Columns

shall be designed to support lanterns with the data given by the Engineer.
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(d) Per BS EN 12767, Annex F, passively safe tubular hollow section steel or
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aluminium posts provided shall have a nominal diameter less than or equal to 89
mm, and a nominal wall thickness of 3.2 mm. Where steel poles are specified in the
Contract Documents, steel grade S355J2H shall be provided.
(e) Aluminium columns shall be finish coated with an anodized aluminium finish
providing resistance to fading, peeling, cracking or corrosion. The guarantee provided
by the manufacturer shall be a minimum of 10 years against fading, peeling, cracking
or corrosion of the finish.
(f) The maximum mass of combined luminaire support and fixtures attached to
breakaway supports shall be limited to 450 kg and the maximum column height shall
not exceed 18.0 metres.
(g) Where slopes are greater than 6:1, no passively safe support shall be used without the
approval of the Engineer. Passively safe supports shall not be used on any
columns mounted on median barriers, concrete or otherwise. No slip base
mechanisms may be used on Qatar roadways.
(h) Columns shall be certified by the manufacturer to comply with BS EN 12767 and shall
achieve the Passive Safety Performance Classes as indicated in Table 15.1.
Table 15.1 – Passive Safety Performance Classes
Pole Support Requirement
Roadway Posted Impact Speed Class*/ Energy
Location
Speed Absorbing Type / Occupant
Safety Level**
(a) 70:HE:1-3
(b) 100:HE:1-3
≤ 40 kph All
(c) 70:LE:1-3
(d) 100:LE:1-3
CBD 100:HE:1-3
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Other 100:NE:1-3
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˃ 40 kph Where columns may fall
100:HE:1-3
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on other carriageways
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below (i.e. flyovers).
HE – High Energy Absorbing
Term Descriptions nt
CBD – Central Business District LE – Low Energy Absorbing
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NE – Non-Energy Absorbing
* Poles shall be procured in order of class per availability from the manufacturer.
** The Occupant Safety Level (OSL) provides for increasing levels of safety by reducing impact
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severity. The preferred level of safety is OSL 3 and shall be procured as first choice when
available from the manufacturer.
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(i) Certification of breakaway support shall be collected from the manufacturer and
submitted for Engineer approval prior to procurement. Certification documentation
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shall confirm the Impact Speed Class, Energy Absorbing Type and Occupant Safety
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Level of the supplied luminaires.
2 Related Equipment
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(a) The column shall be rated to support Cloth Banners up to the length, width and height
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as required in the Contract Documents. Each column shall be provided with a

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240V earthed outlet rated for outdoor conditions in compliance with Section 21 Part
10.2.2 herein.
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(b) When required by the provisions of the Contract Documents, all poles, whether
aluminium or steel in type, shall be supplied with a frangible element or
breakaway base tested and certified to provide passive safety elements as to
be in compliance with BS EN 12767, with special attention to National Annex
(informative) to BS EN 12767:2007.
3 Lighting System Requirements
(a) Work related to the Passively Safe Lighting Column installation provided for in
this specification shall include the supply, installation, testing, commissioning and
putting into satisfactory operation all systems as required by the Contract Documents
and the Specification.
(b) Electrical connections for lighting columns shall be quick disconnect type at ground
level, such that they provide for electrical isolation within 0.4 seconds upon impact of
the lighting pole, and be furnished as required by BS EN 12767:2007 NA.8.
(c) Prior to procurement, the Contractor shall provide shop drawings and supporting
calculations required by the Specification, as well as the provision of all required
supporting technical literature and samples in connection with the acceptance of
proposed equipment approved by Ashghal’s authorized representative.
(d) Due to the long lead times of such equipment, the Contractor shall order the poles
within 1 week of shop drawing approval. The equipment supplied shall include all
necessary items for a complete installation in accordance with the Specification and
other Contract Documents in order to provide for specified luminaire operation.
(e) Contractor shall provide all necessary accessories, wiring and equipment from lamp to
base, feeder pillar to last luminaire, to complete a functional lighting system
regardless of their inclusion in the Contract Documents.
4 Lighting Equipment
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(a) Lighting Columns
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(i) The Passively Safe Lighting Columns shall be procured from an Ashghal-
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approved manufacturer. The manufacturer shall submit no less than three
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references for contact on past performance, supplying previous installed
contract’s contact person, title, agency or company name, phone number and
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e-mail address to Ashghal Design’s and Ashghal Operation and
Maintenance’s authorized representatives as part of the approval process.
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(ii) Columns shall be constructed with their anchor bolts at no more than 100 mm
above ground level. Anchor bolts furnished with the column support shall be
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galvanized steel or stainless steel in type.

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(b) Luminaire
(i) Each luminaire fitted on the Passively Safe Lighting Columns shall meet all
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illumination requirements set forth by Ashghal and the photometric specifics as

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outlined in the Contract Drawings.

(c) Foundations
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(i) Contractor shall submit the dimensions and specification of proposed

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foundations for support of the Passively Safe Lighting Columns. Drawings

and specifications shall be prepared and sealed by a licensed structural
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engineer. The structural engineer shall provide certification that the proposed
foundation design supports the performance of the breakaway mechanism, and
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is designed properly to prevent movement or rotation in the surrounding soil.
15.6.9 Decorative Lighting Columns
1 Decorative lighting systems are non-standard, themed luminaire and pole styles. The
luminaires range from ornate globes known as acorns to four-sided glass fixtures having a
distinct character. The luminaires are mounted on the decorative lighting columns in a post-
mounted arrangement or with a bracket arm. The Contractor shall coordinate final
decorative lighting column and foundation placement with the Engineer to avoid problems
related to the placement of trees, other street furniture and underground utilities.
2 Each Decorative Lighting Column shall be anodized aluminium or galvanized steel as

specified in the Contract Documents. Design of aluminium columns shall comply with
BS EN 40, Part 6 and its incorporated references. Design of steel columns shall
comply with BS EN 40, Part 5 and its incorporated references. Galvanized steel
columns shall be supplied with aluminium cladding sufficient to provide the decorative
features when detailed as such in the Contract Documents.
3 Galvanized steel columns shall be supplied with aluminium cladding sufficient to

provide decorative features when detailed as such in the Contract Documents.
15.7 LIGHTING UNITS
15.7.1 General
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1 Road lighting luminaires (light fitting) shall be semi cut-off or cut off and side entry mounting
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type complete with bowl and integral control gear of rating 100W, 150W, 250W, or 400W,
220-240V, 50Hz as specified in 15.9.
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2 All types of lamps shall be energy saving lamps (LED (light emitting diode), Induction lamps)
manufactured according to International Electrotechnical Commission IEC or International
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Standards, and accepted or approved by Qatar Standards.
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3 The luminaires for roadway lighting shall be to IEC 60598 and shall be capable of achieving
the lighting performance specification requirements set out in the Contract specification in
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accordance with BS 5489 , EN 13201 and ANSI/IESNA RP-008 at the mounting heights
identified within the Contract.
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4 Luminaires shall be side entry mounting and semi cut-off or cut off type with integral control
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gear for use with either 1x 100W, 1x 150W or 1 x 250W, 220- 240V, 50Hz, high pressure
sodium tubular lamp of E-40 base. The E-40 lamp shall have a porcelain skin. The lamp
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supports shall ensure that the lamp position in respect of the optical system remains fixed
throughout its operation. The body shall be made of die cast aluminium and shall be divided
into two compartments.
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(a) The first compartment shall house the optical system with a pressed high purity one
piece aluminium reflector that is anodized and polished. The positioning of the reflector
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shall be such that should it nsslished. Tt lector

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5 The accessories such as ballasts, starters, capacitors etc., shall be pre-wired and pre-
assembled in the rear compartment on a detachable metallic gear tray fixed securely to the
main body of the luminaire in such a way as to ensure effective earth continuity.
6 Special care shall be taken to allow easy maintenance and quick replacement of the
accessories and to minimise the risk of falling.
7 The incoming cable feed terminal block and the earth-screw shall be fixed to either the gear
tray or metallic compartment. A cable restraining device shall be mounted near the incoming
terminal block. All metal parts shall be effectively earthed to the luminaire earth-screw that
shall be readily visible and accessible once access is obtained to the rear compartment. The
spigot entry socket of the luminaire shall be compatible with the column bracket and able to
accept a 125mm long by 50mm diameter or adjustable from 42mm to 60mm diameter spigot.
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15.8 CONTROL GEAR
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15.8.1 General
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1 All items of control gear shall be fitted with shrouds over all terminals to prevent accidental
contact during lamp replacement or routine equipment maintenance. All control gear shall
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have a clearly marked circuit diagram to show its terminal connections in relation to all other
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components. Control gear (choke, capacitor, ignitor etc.) shall be suitable to withstand
temperatures up to 86°C and shall have a purpose made earth terminal. Internal connections
shall be with heat resistant non-hydroscopic insulated stranded copper conductors, cleated
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and with porcelain connectors.

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2 Ballast (choke) shall be closed type polyester filled can. It shall be suitable for single phase
voltage operation and silent in operation. All tappings shall be brought to suitably marked
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standard terminals to which the lamp and supply connections shall be made.
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3 The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance
of + or – 10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the capacitor when fitted. Where the
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capacitor has an aluminium body it shall be provided with a separate earth terminal.
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4 Ignitors shall be mounted within the control gear compartment of the luminaire. Each ignitor
shall be fitted with a device that will detect the presence of a faulty lamp and automatically
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limit the generation of HV pulses. The ignitors shall be suitable for use with the lamp, ballast
and power factor correction capacitor included within the control gear circuit.
15.9 LAMPS
15.9.1 General
1 Lamps shall be energy saving lamps with clear tubular hard glass envelope with E-40 base
suitable for use on 220 - 240 V, 50Hz, AC. Lamps shall be manufactured according to
International Electrotechnical Commission IEC or International Standards, and accepted or
approved by Qatar Standards.
2 Energy saving lamps ( that have a minimum of 50% energy saving than the standard high
pressure sodium vapour gas lamps)shall be:
(a) High Intensity Discharge (HID) ,

(b) Induction lamp types;

(c) Light Emitting Diodes (LED)
(d) and any other types of energy saving lamps accepted and approved by Qatar
Standards .
3 These lamps shall either have a built in or an external ignitor. Initial Lumen output for High
Intensity Discharge (HID) lamps shall be no less than 4,500 lumens/watt for the 50 watt
lamps, no less than 6,500 lumens/watt for the 70 watt lamps, no less than 12,500
lumens/watt for the 100 watt lamps, no less than 17,500 lumens/watt for the 150 watt lamps,
no less than 33,150 lumens/watt for the 250 watt lamps or no less than 48,000 lumens/watt
for the 400 watt lamps,
15.10 LIGHTING SYSTEM FOR UNDERPASSES
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15.10.1 General
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1 The basis for the lanterns for use within both the lighting of the vehicular, pedestrian and
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animal underpasses pertains to lanterns designed for cornice surface mounting within each
underpasses, complete with lamp, fuse and associated control gear. The lighting
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arrangement within each type of underpass shall be based on the use of a common lantern
designed such that it can incorporate either a multi lamp or single lamp luminaire
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arrangement of a variable wattage.
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15.10.2 Vehicular Underpass

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1 The lanterns for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less
than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
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pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
equivalent to the above wattages, complete with all materials as specified herein and in the
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Contract Documents and as required to provide a complete lighting installation.
15.10.3 Pedestrian Underpass

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1 The lanterns for pedestrian underpasses shall consist of either 1x 70 Watt (no less than
6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
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sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps or energy saving lamps,

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complete with all materials as specified herein and in the Contract Documents and as
required to provide a complete lighting installation.
15.10.4 Animal Underpass
1 The lanterns for animal underpasses shall consist of either 1x 70 Watt (no less than 6,500
lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium
vapour luminaires, or Lumen/Watt-equivalent LED lamps, or energy saving lamps complete
with all materials as specified herein and in the Contract Documents and as required to
provide a complete lighting installation.
15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses
1 An underpass lantern shall consist of housing, front cover, reflector, socket, lamp, fuse,
control gear, wiring, latches, screws, washers, pins and other parts composing a complete
unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its
optical housing shall have protection against the ingress of moisture and dust to degree IP55
of IEC529 under all operating conditions.
2 The optical seal which shall include the reflector mounting shall be adequate to maintain this
degree of protection. With the exception of the reflector, lamp holder mounting and
associated cable all other equipment shall be housed at the rear of the optical system and
shall be readily accessible by access through the lantern front plate. These components shall
include the lantern control equipment, associated cable and isolating fuse. The cable
connections to the lampholder within the lantern shall be of the heat resistant type with
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silicon, glass fibre or other approved insulation.
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3 The housing and front cover shall be made of stainless steel.
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4 The reflector shall be made of aluminium sheet of such grade and quality that :
(a)
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The reflecting surface shall have a specular finish.
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(b) The reflecting surface shall have a dense protective coating of oxide not less than 1.2
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mg/cm , applied by the anodic oxidisation process.
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5 The reflector shall be of such material and construction as to provide low brightness and
minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
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non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.

The seal of the optical system shall be accomplished with a gasket material that will not
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deteriorate with age. This gasketing shall be continuous and shall ensure a heat and
weatherproof seal. Suitably located knockouts to suit the cable conduit shall be provided in
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the housing. The lamp socket shall be provided with grips or other suitable means to hold the
lamp against vibration.
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6 The fascia plate of the lantern shall be manufactured from toughened glass protected, if
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necessary due to a high incidence of vandalism by means of the manufacturers purpose

made wire mesh guard.
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7 Between adjacent luminaries a stainless steel ‘in fill’ plate shall be provided such that the
whole assembly gives the appearance of a continuous cornice arrangement. The main sub
circuit cables interconnecting each underbridge luminaire from the underpass isolating
control box shall be routed between fittings within the luminaire or ‘in fill’ plate by means of a
purpose made cable tray arrangement. Within the structure the cabling shall be routed via
galvanized steel conduit cast within the underpass walls and soffit of size suitable to
accommodate the number of single core or multicore cables required whilst maintaining the
stipulated space factor according to the relevant regulations. The cabling shall be either
single core or multi core 6mm² copper conductors within high temperature grade double
insulated or flexible cable.
15.10.6 Underbridge or Undercrossing Lantern and Installation
1 The lantern for use within both the underbridge and undercrossing lighting shall be designed
for directly mounting immediately above the kerb edge of the carriageway and shall be
complete with lamp, fuse and associated control gear. The lighting arrangement shall be
such that it can incorporate either a single lamp of a variable wattage.
2 The underbridge or undercrossing lantern shall consist of housing, cover, reflector, socket,
lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a
complete unit. The lantern shall provide illumination, be mechanically strong and easy to
maintain. Its optical housing shall have protection against the ingress of moisture and dust to
degree IP55 of IEC529 under all operating conditions.
3 The optical seal which shall include the reflector mounting shall be adequate to maintain this
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degree of protection. With the exception of the reflector, lamp holder mounting and
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associated cable all other equipment shall be housed at the rear of the optical system and
shall be readily accessible by access through the lantern front plate. These components shall
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include the lantern control equipment, associated cable and isolating fuse. The cable
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connections to the lampholder within the lantern shall be of the heat resistant type with
silicon, glass fibre or other approved insulation.
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The housing and front cover shall be made of stainless steel.
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5 The reflector shall be made of aluminium sheet of such grade and quality that :
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(a) The reflecting surface shall have a specular finish.

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(b) The reflecting surface shall have a dense protective coating of oxide not less than 1.2
2
mg/cm , applied by the anodic oxidisation process.
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6 The reflector shall be of such material and construction as to provide low brightness and
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minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.
The seal of the optical system shall be accomplished with a gasket material that will not
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deteriorate with age. This gasketing shall be continuous and shall assure a heat and
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weatherproof seal. Suitably located knockouts to suit the conduit shall be provided in the
housing. The lamp socket shall be provided with grips or other suitable means to hold the
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lamp against vibration.

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7 The fascia plate of the lantern shall be manufactured from toughened glass protected, if
necessary due to a high incidence of vandalism by means of the manufacturers purpose
made wire mesh guard.
8 The main sub circuit cables interconnecting each underbridge or undercrossing luminaire
from the underbridge or uncrossing isolating control box Within the structure the cabling shall
be routed via galvanized steel conduit cast within the underbridge or structure walls and soffit
of size suitable to accommodate the number of single core or multicore cables required whilst
maintaining the stipulated space factor according to the relevant regulations. The cabling
shall be either single core or multi core 10mm² copper conductors within high temperature
grade double insulated or flexible cable.
15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps
1 The control gear shall be designed to operate the lamp of the power rating and type indicated
and it shall be able to start the lamp and control it continuously for ambient temperatures up
to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
operating more than one lamp shall not be employed.
of +/– 10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the capacitor when fitted and, if metallic,
shall be provided with a separate earth terminal. The permitted operating temperature of the
capacitor shall be marked on its case.
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3 Each lamp shall operate using only one choke and one capacitor. Any combination of two or
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more capacitors having the equivalent value of capacitance will not be accepted.
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4 Chokes and capacitors shall comply with the relevant British Standard Specification or an
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acceptable International equivalent and shall be fully compatible with the complete
associated operation lamp circuit.
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The ignitor for energy saving lamp shall be of the electronic solid state type and shall be
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arranged so that the ignitor circuit stops working after the lamp has started. It shall be totally
enclosed. The circuit shall include a shunt capacitor to isolate the mains from high frequency
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start pulses; this capacitor may also be used for power factor correction. The length of wiring
between the ignitor and the lamp shall not exceed that recommended by the Manufacturer for
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satisfactory lamp ignition and re-ignition of an extinguished lamp.

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6 The control gear shall meet the following specifications:

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(a) It shall be suitable for 50 Hz, 240 V AC + 10% operation. .

(b) It shall regulate the output power to 12% for the input voltage noted above.
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(c) It shall have an overall power factor of at least 0.85 when operated under rated lamp
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load.
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(d) It shall operate the lamp without affecting adversely the lamp life and performance as
specified herein.
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(e) It shall withstand a 2500 V dielectric test between core and windings.
(f) The choke shall be encapsulated in an approved resin compound and totally enclosed.
7 The lamps for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than
17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
equivalent to the above wattages, complete with all materials as specified herein and in the
Contract Documents and as required to provide a complete lighting installation.
8 The lamps for pedestrian or animal underpasses shall consist of either 1x 70 Watt (no less
than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
sodium vapour luminaires, LED or energy saving lamps with Lumen/Watt-equivalent,
complete with all materials as specified herein and in the Contract Documents and as
required to provide a complete lighting installation.
15.10.8 Underpass, Underbridge or Undercrossing Isolating Box
1 At each underpass, underbridge or undercrossing location an isolating box assembly shall be

provided to control and isolate the respective lighting. This assembly shall be constructed
from either galvanized steel or stainless steel with a hinged vandal resistant lockable front
cover complete with sealing gasket protection against the ingress of moisture and dust to
degree IP54 of IEC529 under all operating conditions providing. A three phase mcb isolator
shall be located within this housing to control the power supplies to each lighting sub circuit.
The galvanized steel conduit providing the cabling routing within the structure shall be
secured at the isolating box assembly by means of a locknut arrangement.
15.11 LED LIGHTING UNITS
15.11.1 Lighting Units
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1 The degree of Ingress Protection provided by the luminaire, including the facility for a
switching device, shall be rated at least IP66 in accordance with EN60529 (IEC529).
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Specification for degrees of protection provided by enclosures (IP code). This shall be
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certified by an independent IP testing and examination laboratory accredited by UKAS or
equivalent accreditation body.
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2 The degree of Impact Protection provided by the luminaire against external mechanical
impact shall be rated at least IK10 (metals and plastics) and IK08 (glass) in accordance with
EN62262:2002 (IEC62262:2002) Degrees of protection provided by enclosures for electrical
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equipment against external mechanical impacts (IK code). This shall be certified by an
independent IK testing and examination laboratory accredited by UKAS or equivalent
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accreditation body.
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3 The luminaire assembly shall be tested and approved by an independent ENEC

(European Norms Electrical Certification) national Certification Body and awarded the
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ENEC mark or equivalent international standards. Contractor shall provide verifiable

certificate featuring contact information of Certification Body.
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4 The luminaire shall be designed and suitably rated to ensure correct operation and
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continuous trouble free service under the prevailing climatic conditions. The luminaire
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shall be designed to withstand the effects of direct sun exposure during the day and dusty
weather conditions including the occasional sandstorm. The luminaire manufacturer shall
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guarantee the performance and life time claims of lumen maintenance and luminaire
life of the luminaire under the stated climatic conditions.
5 The luminaire housing shall be constructed from corrosion resistant marine grade
aluminium alloy conforming to BS EN 1676, 1559-1, 1559-4 and 1706 and powder
coated by an Akzo Nobel approved applicator, or equivalent, conforming to EN12206-1:2004
Paints and varnishes. Coating of aluminium and aluminium alloys for architectural
purposes. Coatings prepared from coating powder.
6 The manufacturer shall supply a RAL colour chart depicting the range of powder coat colours
available for the external finish of the luminaire. Luminaire colour shall be specified at the
time of ordering.
7 The optical assembly and control gear components shall be integral to the luminaire
body.
8 For maintenance the luminaire shall allow tool-less access and incorporate quick
disconnect features and universal fittings. All component parts shall be easily accessible and
securely mounted to prevent accidental falling and manufactured from corrosion
resistant materials or treated to prevent corrosion. The luminaire cover shall include an
optional security feature to enable locking by means of a tool. The cover shall also
incorporate a safety switch to disconnect power on opening and any upward rising
hinged canopy shall be secured in an open position by means of a brace to prevent
accidental closing.
9 The luminaire shall be procured from a prominent luminaire manufacturer that publishes
product specifications measured in compliance with the IEC/PAS performance
requirements or equivalent.
10 The complete luminaire shall be at least 98% recyclable.
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11 The luminaire shall be vandal resistant. The ingress of insects through any system vent or
aperture shall be prevented by means of a filter.
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12 The luminaire shall be compliant with the Waste Electrical and Electronic Equipment
(WEEE) Directive (2002/96/EC) and the Restriction of the use of certain Hazardous
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Substances in electrical and electronic equipment (RoHS) Directive (2002/95/EC).
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13 Each luminaire shall have a barcode securely attached internally within the gear
compartment identifying the luminaires reference/catalogue number, total wattage and
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LED current setting and other attributes as required by Ashghal and as required of the
Enterprise Asset Management System (EAMS). The barcode type shall be compatible with
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the handheld device authorized for use by Ashghal.

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14 All internal and external wiring of the luminaire shall comply with EN60598-1:2008
Luminaires, General requirements and tests and shall be flexible and suitably rated and
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insulated to withstand the voltages and temperatures encountered in service.
15 Any luminaire wiring passing through metal shall have suitable grommets or otherwise be
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protected to avoid abrasion of the insulation.

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16 All luminaire terminals and supply connections shall comply with EN60598-1:2008. The
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conducting material of any terminal block shall be made of brass and shall have screw down
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plates bearing on the wires. Terminals where screws bear down directly on wires will not be
acceptable.
17 Luminaires shall be earthed in accordance with EN60598-1:2008. An earth terminal forming

part of the luminaire body shall be provided. All parts of an earth terminal shall be made of
brass.
18 Luminaires shall be “future proofed” by allowing the LED modules to be upgraded easily in
situ, as LED efficiency improves. Upgrading of luminaires, or replacement of faulty
components, with manufacturer approved components shall not have any detrimental
impact whatsoever on the luminaires’ manufacturer warranty. Prototypes shall not be
accepted.
15.11.2 Lighting Performance

1 Highway luminaires shall be suitable to achieve the lighting class standards as detailed in the
Qatar Design Management Manual, as referenced in ANSI/IESNA RP-008, and as applicable
to Primary, Secondary and Tertiary roads in The State of Qatar, under the control of Ashghal
and other areas as required.
2 The luminaire shall be compliant with EN60598-1:2008 Luminaires. General

requirements and tests, and EN60598-2-3:2003 Luminaires. Particular requirements.
Luminaires for road and street lighting.
3 The luminaire shall be able to restrict glare and control obtrusive light in accordance with the
full “cut-off” and “semi cut-off” concepts and associated luminous intensity classes defined in
ANSI/IESNA RP-008 or an equivalent, Ashghal-authorized standard. Individual project
contract drawings and design specifications shall detail the luminous intensity class
requirement.
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4 The luminaire shall control light output to limit light pollution and minimise sky glow in
accordance with Commission Internationale de l'Éclairage (CIE) 126-1997 Guidelines for
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minimizing sky glow and meet the requirements therein for maximum permissible
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upward light output ratio (ULOR) expressed as the percentage of luminous flux
acceptable in each of four different Environmental Zones.
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The efficacy of the luminaire is given by the total lumen output divided by the power into the
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system and shall be equal to or greater than 100 lm/w (lumens per watt) operating within the
climate conditions as stated herein. The contractor shall obtain a statement from the
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luminaire manufacturer declaring that quoted performance figures correspond to the stated
ambient air temperature and ensure that the specifics of operating in the Qatar environment
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are written into any applicable section of the manufacturer’s warranty agreement.
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15.11.3 Thermal Management

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1 The luminaire shall be capable of withstanding severe climate conditions, as stated in

Section 21, Part 1. General Provisions for Electrical Installation, clause 1.1.14.
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2 As a minimum, manufacturers shall use 50 ˚C as the night time ambient temperature

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with 95% humidity.

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3 The luminaire shall be designed to provide satisfactory heat dissipation for any powered
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component parts and maintain safe operating temperatures at all times under the stated
climatic conditions. Heat dissipation shall be by passive thermal management, active or
mechanical cooling is not acceptable.
4 All materials used in the luminaire shall be resistant to high temperature UV (ultra violet)
exposure and be 90% UV-stable.
5 The luminaire shall incorporate a passive thermal management system, active cooling such
as fan assisted systems will not be accepted. The manufacturer shall demonstrate that the
luminaire is suitable for continuous operation in the Qatar environment. Within the stated
climate conditions the LED junction temperatures shall be shown to remain within the range
required to limit the risk of accelerated degradation of the LEDs based on the stated life
expectancy of the luminaire.
6 Junction temperature cannot be measured directly and must be derived using calculation
formulae and temperature measurements read from a thermocouple device attached to a
series of defined reference points (thermal pads) on the outer casing (package) of the LED.
Thermal verification testing is carried out as a laboratory based operation with ambient
conditions simulated.
7 The luminaire manufacturer shall submit a statement declaring that quoted LED
performance figures correspond to the stated ambient air temperature and ensure that the
specifics of operating in the Qatar environment are written into any applicable section
of the warranty agreement.
8 The maximum allowable ambient temperature for the LED lighting shall be stated, in
which the LED lighting can operate without adversely affecting any components life,
luminaire light output or colour stability. This shall take into consideration the maximum case
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temperature of the driver and the design LED junction temperature.
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9 Manufacturers shall state the predefined critical temperature level at which the dim down and
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switch off protection events occur and relate to junction temperature and ambient
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temperature. The luminaire shall be constructed in such a way that this protection
method shall not occur during climate conditions stated within this specification.
15.11.4 Testing
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1 LED Luminaire lighting performance shall be measured using an independent
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photometric testing laboratory accredited by UKAS or equivalent accreditation body. The test
procedure and measurements shall be carried out in accordance and compliance with
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IES_LM-79-08 Approved Method: Photometric Measurements of Solid State Lighting

Products. The photometric test report shall list all significant data for each SSL product
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tested together with performance data and also pertinent data concerning conditions of
testing, type of equipment, and reference standards. The photometric test procedure shall
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also be used to calculate correction factors in allowance of the stated climate conditions.
2 Photometric data for each luminaire optical setting shall be available in electronic file
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format in accordance and compliance with IES_LM-63-02 Standard File Format for
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Electronic Transfer of Photometric Data and Related Information and EN13032-

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1:2004+A1:2012 Light and lighting. Measurement and presentation of photometric data of

lamps and luminaires. Measurement and file format. The photometry files shall be
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compatible for use with industry recognised road lighting design software packages or as
requested by Ashghal and include applied correction factors specific to the declared
ambient conditions.
3 Lighting performance of the LED luminaire in terms of design spacing’s relative to a

specified road lighting class should be comparable to a modern HID lamp based
luminaire with similar lumen output.
4 The luminaire manufacturer shall submit a statement declaring that quoted photometric
performance figures correspond to the stated ambient air temperature (not LED junction
temperature) and ensure that the specifics of operating in the Qatar environment are
written into any applicable section of the warranty agreement.
5 The luminaire shall be tested in accordance and compliance with EN62471:2008

(IEC62471:2006) Photobiological safety of lamps and lamp systems or an equivalent
standard. Any assumptions made during testing shall be clearly stated.
6 The luminaire LED light source shall be tested in accordance and compliance with
IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources. The
LM-80-08 test report produced for the LED light source shall meet the eligibility
criteria necessary for submission to the U.S Department of Energy (DOE) Energy Star
Program Requirements for Solid State Lighting Luminaires.
15.11.5 In Situ Temperature Measurement Test (ISTMT)
1 In order to relate the LM-80 test to the luminaire and stated climatic conditions, testing shall
be completed that simulate this application. This shall be achieved by In Situ
Temperature Measurement Test (ISTMT) which follows ANSI/UL 1598-2004 Luminaires.
2 The luminaire manufacturer shall provide a written undertaking to the satisfaction of

Ashghal\s authorized Engineer to warranty the materials and performance as follows:
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(a) LED arrays shall have a written warranty for a minimum of 50,000 hours at the ambient
temperature specified herein and shall be replaced on a one for one basis upon failure.
An LED array will be deemed to have failed when:
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(b) equal to or greater than 10% of the individual LED chips in an array has failed or an
array does not provide the required lumen maintenance (L70).
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Drivers shall have a written warranty for a minimum 50,000 hours and shall be
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replaced on a one for one basis.
(d) Luminaire housing and all external components such as; lenses, gaskets & fastenings
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and the fixture finish shall have a written warranty for a minimum twenty (20) years
against the deterioration of, but not limited to, mechanical failure, UV degradation,
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corrosion, yellowing, blistering, chalking, cracking, peeling or fading.

(e) The Warranty shall be transferable without limitations in its entirety to Ashghal, Public
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Works Authority, Qatar.

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3 Equivalent or more onerous standards can be proposed, by the manufacturer, as an

alternative to the detailed standards, with the exception of Qatar documents. Evidence shall
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be submitted detailing the equivalent or more onerous sections that deviates from the
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intended standard.
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15.11.6 Control Gear

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1 The luminaire control gear (driver) shall be produced by a prominent manufacturer of

semiconductor components and comply with IEC 62384 DC or AC supplied electronic
control gear for LED modules - Performance requirements. The manufacturer shall
confirm that the packaged driver assembly is fabricated from high quality integrated
circuit components including long-life electrolytic capacitors and provide data relating to the
reliability of the device, in the climatic conditions stated in this specification.
2 The drivers shall be encapsulated / potted and Class II double insulated (IEC61140) and
have a minimum energy efficiency of 85% and power factor ≥0.9 (full load). The control gear
shall feature Surge Protection Device (SPD) for lightning strikes (IEC62305), short-circuit
protection and transient overvoltage protection (IEC61643-1 / IEC61000-4-5).
3 The LED drivers shall be housed on a removable gear tray accessible with the luminaire
cover open and be compatible with the Qatar power supply. The supply cable shall pass
through the mounting post, or bracket, directly into the luminaire through an M20 cable gland
located at the base of the luminaire mounting socket.
4 For protection in the event of temperatures reaching predefined critical levels, both
LEDs and drivers shall have thermal protection, which will initially dim down and
eventually switch off the light. Manufacturers shall state the predefined critical
temperature level at which the dim down and switch off protection events occur and
relate to junction temperature and ambient temperature. The luminaire shall be
constructed in such a way that this protection method shall not occur during climate
conditions stated within this specification.
5 The driver system shall be compatible with Lighting Control Systems / Lighting
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Management Systems (LMS), using both analogue (1-10V) and Digital Addressable
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Lighting Interface (DALI) protocols including WiMAC or other similar Ashghal-approved
driver system. The driver system shall also be capable of being configured for
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single, and multi-stage, stand-alone dimming configurations when not connected to a
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CMS.
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The drivers shall be programmable and permanently configured to operate under the
principle of “constant flux” output or maintenance factor harvesting or similar, Ashghal-
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approved configuration method. During this process light output is initially dimmed to an
equivalent end of life level value and then the operating current is gradually increased
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throughout service life to compensate for lumen depreciation and maintain a constant
lighting level. The advantage of this system is to give energy savings and improve LED
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life and reliability. The manufacturer shall provide details of how this facility is maintained
following replacement of a faulty driver or LED array.
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7 The driver shall be capable of operating within the climate conditions previously
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described and shall have documentation and certification supporting the claimed
minimum life expectancy of 50,000 hours in the stated conditions within this
specification.
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8 The driver manufacturer’s device data sheet will provide specification details and the
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maximum permissible ambient temperature range in which the driver can operate (free air
convection) at the defined driver current. The luminaire manufacturer shall
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demonstrate that the LED driver is suitable for continuous operation in the Qatar
environment. Within the stated climate conditions the driver compartment enclosure shall be
shown to remain within the range required to limit the risk of driver failure during
operation based on the stated life expectancy of the luminaire.
9 The luminaire manufacturer shall submit a statement declaring that quoted driver
performance figures correspond to the stated ambient air temperature and ensure that the
specifics of operating in the Qatar environment are written into any applicable section
of the warranty agreement.
10 The luminaire shall conform to CE marking directives including the European

Electromagnetic Compatibility (EMC) Directive EN 61000-3-2:2009 (IEC 61000-3-
2:2009) Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic
current emissions (equipment input current ≤ 16 A per phase)
15.11.7 LED Lamps
1 The LEDs shall be produced by a Ashghal Approved manufacturer of solid state lighting
(SSL) components and comply with the related standards and guidelines set by the
Illuminating Engineering Society of North America (IESNA) and the JEDEC Solid State
Technology Association and approved by Qatar Standards.
2 The light source is required to control light output with the aim of optimising luminaire
performance and efficiency in relation to the specific lighting application. The luminaire, or
luminaire series, shall provide the facility for varying luminous flux output ranging from 5klm
up to at least 40klm using an appropriate number of LEDs and a suitable control method for
each different lumen package.
3 The luminaire LED module shall comply with International Electrical Commission
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Publicly Available Specification IEC/PAS62717 LED modules for general lighting –
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Performance requirements.
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4 The LED arrays shall be capable of operating within the climate conditions previously
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described and shall have documentation and certification supporting the claimed minimum
life expectancy of 50,000 hours at L70 in the stated conditions as within this specification.
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Technical details shall be provided of the light source optical system and range of optics or
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optical settings available for each model of luminaire including performance
characteristics. The optical system is required to control light output with the aim of
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optimising luminaire performance and efficiency in relation to the specific lighting

application. The system should meet the lighting requirements of most rights of way
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types and configurations and maximise the “light output ratio” (LOR) of the luminaire.
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6 The inadvertent failure of any LEDs during the life of the luminaire shall not bring about any
reduction in uniformity of light output. Therefore, the multi-layer method of light distribution
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shall take precedence over multiple spot methods.
7 Diffuser systems may be required for some lighting applications to eliminate the effect of
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multiple-source shadows.
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8 Chromaticity tolerance and associated colour consistency of luminaire LED modules

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shall be measured in terms of the CIE 1931 chromaticity diagram and the CCT
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quadrangles defined by the American National Standards Institute (ANSI) C78.377-

2008 Specifications for the Chromaticity of Solid State Lighting Products for Electric Lamps.
The ANSI quadrangle is made up by smaller quadrangles, commonly referred to as bins. The
x y chromaticity components of each LED module shall be enclosed by one bin and the bin
size shall not exceed a 4-step MacAdam ellipse. The binning process shall be in compliance
with National Electrical Manufacturers Association (NEMA) SSL 3:2010 High-Power
White LED Binning for General Illumination.
9 The chromaticity shift shall be measured and reported in accordance with IES_LM-80-08
Approved Method: Measuring Lumen Maintenance of LED Light Sources.
10 For highway lighting the Correlated Colour Temperature (CCT) of the light emitted from the
luminaire shall be in the range ≥4000K with a Colour Rendering Index (CRI) of ≥60. The
manufacturer shall state the CCT ranges available with a ±275K warranted window. The CCT
and CRI shall include the effects of colour shift over the life of the luminaire. Other CCT
ranges may be applicable to individual projects and manufacturers shall be notified as
required.
11 Lumen maintenance (L) is the luminous flux emitted by the light source at any specified time
during its operational life and is expressed as a percentage of the luminous flux
emitted at the start of life (L%). The rated lumen maintenance life of the LED light source
shall not exceed L70, or 30% lumen depreciation at the specified temperature conditions.
12 The luminaire manufacturer shall define the estimated service life of the light source in terms
of operating hours and rated lumen maintenance. The minimum standard expected shall be
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50,000 operating hours at L70 at the temperature conditions specified herein.
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13 The method of deriving rated lumen maintenance life beyond the limits of lumen
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maintenance determined from actual measurements shall be demonstrated. The method for
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projecting the lumen maintenance of LED light sources from the data obtained by the
procedures found in IES document LM-80-08 shall be in accordance and compliance
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with IES_TM-21-11 Projecting Long Term Lumen Maintenance of LED Light Sources.
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14 In combination with rated life predications the reliability of the LED modules shall also be
expressed in terms of the percentage (fraction) of failures in accordance with IEC/PAS
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62722-2-1:2011 Luminaire performance - Part 2-1: Particular requirements for LED

luminaires. The failure fraction (Fy) corresponds to the percentage of LED‟s that fail
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before end of rated life. This failure fraction expresses the combined effect of all
components of a module including mechanical, as far as the light output is concerned. The
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effect of the LED could either be less light than claimed or no light at all.
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15 The failure fraction shall also be expressed in terms of its component parts, gradual failure
fraction (By) and abrupt failure fraction (Cy). The reliability curve relative to operating hours is
calculated using statistical formulae and data gathered under test conditions during luminaire
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monitoring periods.
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16 Luminaire maintenance factors (LMF) to follow model used in BS5489-1:2003+A2:2008

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Annex D Table D1 with figures extrapolated to extend cleaning cycle interval up to 6

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years and also adjusted to take account of environmental conditions specified herein.
17 Lamp flux maintenance factor (LFMF) shall be calculated by the manufacturer in accordance
with calculated lumen depreciation relative to a predefined cleaning cycle interval. Currently
the perceived cleaning interval is biannually due to the intense dust laden atmosphere.
15.11.8 Quality Criteria for LED Lighting
1 Manufacturers shall submit data in accordance with IEC/PAS 62717 Performance

requirements – LED modules for general lighting and IEC/PAS 62722 Performance
requirements – LED luminaires for general lighting.
15.11.9 LED manufacturers data
1 Manufacturer shall provide a standardised set of quality criteria, measured in

compliance with the appropriate standard. The performance claims shall be matched against
traceable data. The performance data required is summarised below and shall be headed
Quality Criteria:
(a) Rated input power (in W)

(b) Rated luminous flux of the luminaire (in lm)
(c) luminaire efficacy (in lm/W)
(d) Luminous intensity distribution
(e) Photometric code
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(i) Rated Colour Rendering Index (CRI)
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(ii) Correlated Colour Temperature (CCT in K)
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(iii) Rated chromaticity co-ordinate values (initial and maintained)
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(iv) Maintained luminous flux
(f)
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Rated life (in h) of the module and the associated rated lumen
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(g) maintenance (Lx)
(h) Failure fraction (Fy), corresponding to the rated life of the module in the
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(i) luminaire
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(j) Ambient temperature (ta) for the luminaire

(k) Power Factor
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(l) Intensity Distribution

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(m) Drive Current

(n) Optical Risk Group
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2 This data shall be submitted on an Ashghal-approved form. Forms shall be submitted to

Ashghal for approval prior to submitting data for consideration. Further data shall be
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provided to evidence compliance with all aspects of this specification. Additional data shall be
provided as and when requested by Ashghal.
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15.12 OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION
15.12.1 General
1 The basis for the lanterns for use on the overhead sign gantries or bridges for the illuminating
of overhead guide signs mounted on the sign support structure or on the gantry sign walkway
supported on the gantry sign support brackets. The lanterns shall be complete with lamp,
isolating fuse and associated control gear.
15.12.2 Sign Gantry Lantern
1 The lanterns shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
75% of the initial luminous flux.
2 The lantern shall provide efficient illumination, be optically sealed, mechanically strong and
easy to maintain.
3 The reflector mounting, wiring terminals and control gear components shall be readily
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accessible. When closed for operation, the optical assembly shall be sealed to provide
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protection against the ingress of moisture and dust to degree IP55 of IEC529 under all
operating conditions.
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4 The seal between the refractor and the housing shall be adequate to maintain this degree of
protection. The refractor shall be held in such a manner as to allow for expansion and
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contraction of the refractor. Cable connections to the lamp holder within the lantern shall be
of the heat resistant type with silicon, glass fibre or other approved insulation.
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5 The optical system shall consist of a hydroformed aluminium primary beam reflector which
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shall be precisely profiled and contoured to distribute light across the inner surface of the
refractor. The prismatic refractor shall be of moulded borosilicate thermal shock-resistant
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glass. The inner surface shall have an intricate array of prisms to direct light across the face
of the sign. The outer surface shall be smooth to facilitate self-cleaning. The reflector shall be
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of a retro-dispersing type designed to eliminate the halo of excessive luminance to assure

more uniform sign luminance.
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6 The terminal board shall be located beneath the reflector at the conduit entry and shall
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accommodate 10 mm electric cables.
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7 The reflector shall be fastened to the housing by means of a minimum of four stainless steel
screws with keyhole slot to facilitate easy removal and replacement. Levelling pads are to be
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provided on the inside and bottom of the main housing to permit accurate installation.
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8 There shall be mounting within of the stainless steel housing to permit the lantern to be
mounted directly to the supporting structure.
9 The refractor shall be form-fitted to the stainless steel door frame and shall have a single
piece gasket with a sealing pad to effectively seal the assembly and housing. The assembly
shall be fastened to the housing by means of separable hinges at the front and spring
tempered, stainless steel at the rear. The lamp socket shall be provided with grips or other
suitable means to hold the lamp against vibration.
10 The terminals of all ballasts, capacitors and control gears shall be shrouded.
11 Each sign lighting system shall be subject to the approval of the Engineer. Particular attention
shall be given to the mechanical strength of all components, and to the security of their
method of the sign supports.
15.12.3 Sign Gantry Lantern Control Gear and Lamps
1 The control gear shall be designed to operate the lamp of the power rating and type indicated
and it shall be able to start the lamp and control it continuously for ambient temperatures up
to +55°C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
operating more than one lamp shall not be employed.
of + or –10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the shell and be provided with a separate
earth terminal. The permitted operating temperature of the capacitor shall be marked on its
case.
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3 Each lamp shall operate using only one choke and one capacitor. Any combination of two or
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more capacitors having the equivalent value of capacitance will not be accepted.
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4 Chokes and capacitors shall comply with the relevant British Standard Specification or an
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acceptable International equivalent and shall be fully compatible with the complete
associated operation lamp circuit.
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The control gear shall meet the following specifications:
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(a) It shall be suitable for 50 Hz, 240 V AC + 10% operation.
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(b) It shall regulate the output power to 12% for the input voltage noted above.
(c) It shall have an overall power factor of at least 0.85 when operated under rated lamp
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load.
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(d) It shall operate the lamp without affecting adversely the lamp life and performance as
specified herein.
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(e) It shall withstand a 2500 V dielectric test between core and windings.
(f) The choke shall be encapsulated in an approved resin compound and totally enclosed.
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6 The lamps shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
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lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
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33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
75% of the initial luminous flux.
15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables
1 At each sign gantry location an isolating (safety) shall be provided at walk way level of the
structure. It shall be fabricated galvanized steel complete with a vandal resistant hinged
access door. A three phase mcb isolator shall be located within this housing to control the
power supplies to each lighting sub circuit. The galvanized steel conduit, secured to the
gantry structure by means of purpose made saddles to suit the size of conduit, providing the
cabling routing within the structure shall be secured at the isolating box assembly by means
of a locknut arrangement. The size of the conduit shall be suitable to accommodate the
number of single core or multicore cables required whilst maintaining the stipulated space
factor according to the relevant regulations. A 3-phase mcb isolator shall be located within
the isolating (safety) switch to control the lighting sub circuit upon each gantry structure. The
cabling shall be either single core or multi core 10mm² copper conductors within high
temperature grade double insulated or flexible cable.
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15.13 PHOTO ELECTRIC CONTROL CELL
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15.13.1 General
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1 Photo electric control cells shall comply with the requirements of BS 5972 and offer a Class II
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protection from electric shock as defined in IEC 60598.
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2 Unit must be completely weatherproof, hermetically sealed against the ingress of moisture. It
shall be resistant to vibration or change in temperature. It shall be housed in a strong impact
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resistant low profile translucent housing, the surface of which shall be non- oxidizing and
impervious to deterioration.
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3 The photo electric control unit (PECU) shall be guaranteed for a period of not less than six
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years, failures within that period of time to be replaced free of charge.

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°
4 They will be capable of working in an ambient temperature of up to + 60 C.
5 The operation level should be preset to ON 80/100 Lux the ratio of ON to OFF should be
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approximately 1:2. There shall be no means of manual adjustment to the PECU’s calibration
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and it shall not need to be orientated to operate as required.

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6 There should be a minimum 15 second delay to prevent the unit from functioning due to short
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period high illumination such as lightning etc.
7 The power supply to the PECU shall be 240V 50Hz. A.C with a contact output rating of 30A at
240V (resistive).
8 The PECU and associated relay or switching device shall have pre matched responses and
housed in the same envelope. The contact rating shall be 1500-Watts (1800 V.A) and should
be fitted with a snap action to prevent chatter. In the case of the load to be switched then the
PECU can switch directly, a contactor shall be used.
9 The photocell shall be located within the road lighting feeder pillar such that it can be easily
removed. It shall be housed within a small compartment with an acrylic fascia plate set into
the surface of the feeder pillar for the satisfactory operation of the photocell. The control
circuitry for the correct switching of the road lighting will be housed within the adjacent feeder
pillar. The associated specification requirements will be dealt with within that section of the
specification.
10 The upper LED luminaire cover shall have the facility for installation and wiring of one of the
following devices: an integral miniature photocell, NEMA socket (detachable photocell),
telemetry device. This facility shall be included within the IP testing.
15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS
15.14.1 General
1 Cutouts in columns shall be phenolic moulded, three phase, and suitable for looping two 4
Core 25 mm XLPE/SWA/PVC cables.
2 Cutouts shall :
(a) Incorporate miniature circuit breakers complying to BS EN 60898 with a minimum
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breaking capacity of 4kA.
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(b) Be of the combined single phase and neutral type.
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(c) Incorporate an earth terminal.
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(d) Be suitable for concentric or PVC armoured cables of up to 25mm2 cross-sectional
area with capacity for looping in and out.
(e) Have all metal parts tinned. nt
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(f) Be provided with a minimum of 2 fixing screws.
(g) Be manufactured from material which is non-hygroscopic and non-tracking.
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3 Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for the
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use of miniature circuit breakers 6 A, 10A or16 A ratings, selected from the Table 15.2 below:
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Table 15.2
Ratings of Miniature Circuit Breakers
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Wattage 50W 70W 100W 150W 250 W 400 W
For 1 Lamp 6 6 6 6 10 10
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For 2 Lamps 6 6 6 10 16 16
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4 The cutouts shall comply with the 16th Edition of the IEE Wiring Regulations.
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5 A cutout used as a means of isolation shall have the facility for padlocking.
6 The service cutout shall have a moulded enclosure, offering a minimum protection of IP22,
capable of withstanding severe impact.
7 Separate terminals shall be provided for live, neutral and earth conductors complete with
terminal shields to prevent accidental contact with all live conductors.
8 Cutouts shall be sized to accommodate the designated cables, but with a minimum of
25mm2 cables.
9 Cable armouring shall be bonded as an integral part of the cutout, and complete with cable
armour clamp shrouds.
10 The cutout shall be suitable for mounting on a wooden backboard or DIN rails.
11 Where there is a requirement for the use of an isolator they shall incorporate in-built fused
loop terminals for the feeds to signs, bollards etc.
12 All isolating devices shall be double pole for single-phase systems and four poles for three
phase systems.
13 All isolators shall be rated to suit the local environmental conditions of Qatar where these
differ from those stated in BS EN 60947-3
15.15 FEEDER PILLAR
15.15.1 General
1 Road lighting feeder pillars shall be totally enclosed weatherproof with fibreglass reinforced
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polyester cabinet of ground mounting type complete with accessories suitable for mounting
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outdoor..
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15.15.2 Cabinet
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1 The feeder pillar cabinet, unless previously approved by the Engineer, shall be of fibreglass-
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reinforced polyester and ultra violet ray resistant. The cabinet surface shall be totally weather
and corrosion resistant with a completely smooth exterior. The outer 0.5mm - 1.0mm should
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consist of pure polyester. The colour of the cabinet shall be grey. The colour shall be
completely light stabilised and impregnated from the surface through the thickness of the
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material.
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2 Pillars shall be ground mounting type by means of a steel frame with concrete foundation.
The cabinet shall have a base frame with a minimum ground clearance of 200mm between
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the body and the mounting area (bottom). The base frame shall have at least four holes to
bolt down the pillar to the concreted steel frame. The cabinets base frame shall be
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removable. The feeder pillar shell shall incorporate lifting devices for the safe movement of
the feeder pillar.
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3 The cabinet top (canopy) shall be arranged so as to prevent the ingress of rainwater and
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provide air circulation.

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4 The cabinet shall be provided with a front door complete with internal hinges and fixing
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screws fixing at top and bottom. A tamper proof lock will be provided centrally and all locks
shall operate by a standard master key. Two keys for each pillar shall be provided. The door
closing will have a perfect weatherproofing arrangement. The enclosure shall have a
designated IP rating of IP54 in accordance with IEC 60529.
5 Approximate cabinet size shall be 1000mm high by 620mm length by 300mm width..
6 Natural ventilation shall be provided to limit the temperature rise to the manufacturer’s
recommendations. Such ventilation shall not reduce the stated IP rating of the cabinet and
shall be screened to prevent the entry of vermin. Where recommended by the manufacturer
dust filters shall be provided.
7 A data plate shall be fixed to the inside of the pillar detailing information as deemed
necessary by the PWA and/or the Engineer.
8 Detailed distribution board schedules are to be provided within the each feeder pillar these to
be located on the inside of the cabinet and stored in a weather protected plastic pocket
securely fixed to the shell of the housing.
15.15.3 Components of Feeder Pillars
1 1 No. 200Amp mains breaker (MCCB) of three phase 415V - interrupting capacity according
to BS 3871:
240V – 85kA
415V – 35kA
A facility to lock off the assembly in the open position shall be provided.
2 1No. 200Amp 4 pole magnetic contactor, three phase with coil voltage of 240V within an IP
54 enclosure. The contacts of the contactor shall be fitted with a snap action to prevent
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chatter.
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3 A control circuit shall be provided connected to the control coil of the contactor. The circuit
shall be protected by means of a 4A HRC control fuse within a weatherproof enclosure. The
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control circuit shall be such that in the event of a failure of the photocell control unit a time
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switch identified below will override the operation. In addition a manual override switch shall
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be provided to operate the road lighting at times outside the periods during which the lights
are normally operational.
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4 The time switch shall be a 24-hour dial time switch motor driven single phase 30 Amp. 220 -
240V 50 Hz. with a clock accuracy of + or – 5minutes/year and shall have a 48-hour
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synchronous spring reserve to maintain clock operation and output switching during power
supply failure or disconnection. Time switch should be protected with a HRC fuse or MCB.
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Arrangement for connecting a photoelectric control switch shall also be made within the pillar.
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5 A 3-phase MCB metal clad or plastic distribution board complete with single pole 240V
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MCB’s of interrupting capacity according to BS EN 60898. The number and size of the
outgoing circuits shall be as per the feeder pillar schedules. Terminations shall be capable of
accommodating sub circuit cable of size 25mm2. There shall be at least 25% spare outgoing
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circuit capacity.
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6 MCB’s and protective devices shall be rated to withstand a minimum short-circuit current of
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9kA.
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7 Neutral terminal bar shall be provided separately. Neutral conductors shall be insulated from
earth to allow use on TN-S systems. The neutral connections shall have separate
connections for each outgoing cable. Where a neutral busbar is provided it shall be mounted
in parallel with the phase busbars and arranged so that each neutral connection is physically
identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of
the feeder pillar and shall be of sufficient length to accommodate a connection for each
circuit including 25% spare capacity. The neutral busbar shall be coloured black and the
earth busbar coloured green and yellow.
8 Busbars shall be of full rating having taken into account any holes, they shall be constructed
from high conductivity copper and mounted on insulators and mounted at the rear of the
feeder pillar. Busbars shall be insulated with non-hydroscopic, non-tracking insulation. All live
parts shall be screened.
9 Insulated dividing barriers shall be provided between both phase contact assemblies and
between phase and neutral.
10 Each feeder pillar shall accommodate at least 1No. brass cable gland with locknut, earth tag
and PVC shroud for the incoming supply cable together with individual brass cable glands
25mm CW gland according to BS 6121 complete with lock nuts, earth tags and PVC shrouds
for all outgoing cables, including an allowance for spare capacity, for stranded copper cables
up to 25mm² 4 core XLPE SWA PVC.
11 Colour-coded leads shall identify all wiring for phase and neutral cables. Outgoing circuits
shall be labelled with the circuit reference and circuit breaker rating. Wherever possible all
internal wiring shall be enclosed in trunking or conduit.
15.16 ROAD LIGHTING CABLES
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15.16.1 Underground Cables
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1 Underground road lighting cable shall be copper stranded 10/16/25mm² x 4 core XLPE SWA
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PVC cable of stranded copper conductor 600/1000 VAC.
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Cables shall be low tension 600/1000 volt multi core stranded copper conductors, insulated
with XLPE compound, core laid-up, extruded PVC tape bedded, steel wire armoured and
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PVC sheathed overall underground cables to BS 5467: 1977.
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3 The cable shall be capable of withstanding vigorous climatic conditions of ambient

temperature up to 50°C (the temperature can be accompanied by a relative humidity of up to
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100% at 30°C).
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4 It should also be noted that cables can be buried in sand and laid partly in ducts at a depth of
up to 600mm in footpaths and 750mm in roadways. The ground temperatures can vary from
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35-40°C in summer to 8-12°C in winter. Cable drums may be stored in the open for up to 1
year and will be exposed to direct sunlight. Accordingly, cables shall be designed to withstand
such conditions without deterioration of the electrical or mechanical properties.
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5 Cables shall have the following construction details:

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(a) Conductors: High conductivity stranded copper - shaped conductors shall

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comply with BS 6360: 1981 with XLPE insulation.

(b) Bedding: Bedding shall be an extruded layer of XLPE compound.
(c) Colour of Cores: Red, Yellow, Blue and Black.
(d) Armouring: Single layer of galvanized steel wire.
(e) Finish (over sheath): Extruded black PVC over sheath which conforms to BS 6346:
1987 for thickness and to BS 6746: 1987 for properties. The
external surface shall be embossed with the voltage
designation, cable size and manufacturers name
15.16.2 Packing of Cables
1 Underground cables shall be packed in sealed wooden cable drums each of 500 metres
length with a plate stating the following details:
(a) Manufacturer's name and country of origin

(b) Cable type and size

(c) Length of cable per drum
15.16.3 Insulated PVC Sheathed Circular High Temperature (85°C)
1 Flexible cable should be of conductors of high conductivity copper stranded wires, 2.5 sq.
mm, insulated with high temperature PVC compound, three cores, green or yellow, blue and
brown, twisted together, filled and sheathed with high temperature PVC compound,
300/500V.A.C. according to BS 6141, Table 15 or equivalent norm.
15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES
15.17.1 General
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1 Marker tape shall be installed wherever cables are to be directly buried in the ground to warn
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of the presence of power cables.
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15.17.2 Material & Quality
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1 The marker tape shall be of low density polyethylene, of thickness at least 100 micron. Its
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width shall be 40cm and be yellow in colour, with black marking indicating the presence of
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road lighting cable in both English and Arabic. Its location in respect of the cable position is
identified within the Contract documentation.
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2 The material shall be colour fast, and resistant to chemical action in typical ground conditions
experienced in Qatar. These may vary from extremely wet to extremely dry, and with very
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high salinity. The ground temperature may vary from 0 to 40°C.

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3 The material shall be mechanically durable. The manufacturer shall demonstrate the
samples complying with this specification have been tested for compliance with BS 2782,
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Part 3, Method 326A to 326C or an equivalent standard.

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15.18 MARKER POSTS

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15.18.1 General
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1 Where instructed by the Engineer, the Contractor shall install marker posts and slabs. These
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shall be of reinforced concrete, steel or heavy duty plastic of an approved type suitable for
use in Qatar. Unless instructed otherwise pre-cast reinforced concrete or equally approved
marker posts or slabs shall be installed at intervals of not more than 50m along all
underground cable routes, joint pits (if any), at all changes of direction and at both ends of
road crossings.
15.19 EARTHING
15.19.1 General
1 The integrity of the earthing system within the road lighting network shall be maintained.
2 Each item of equipment shall be individually effectively earthed within each lighting assembly
and feeder pillar by means of a dedicated earth to a central earthing point. This shall be
regardless of any other terminals available. All connections shall use crimped terminations.
2 2
3 For circuit conductors of 16mm and 25mm a circuit protective conductor of cross-section
2
not less than 16mm shall be incorporated.
4 All removable metal doors or metal frames shall be earth bonded.
5 Within the feeder pillar the central earthing point shall be connected to the incoming earth
provided by QGEWC.
6 At each feeder pillar location an earth rod shall be installed complete with an approved earth
pit and cover plate. It shall have a resistance to true earth of not more than 10 ohms. The
size of the earth rod shall be 16mm by 2.5m in length. It shall be driven to a depth that
penetrates the summer water table by at least 1m. It shall be connected to the central
earthing point of the feeder pillar via a bare stranded copper conductor of cross-sectional
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area 70mm .
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7 At the end of each lighting sub circuit an additional earth electrode as detailed above shall be
connected to the central earthing point within the last lighting column base compartment. The
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connection between the earth electrode and the column central earth terminal shall be via a
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2
bare stranded copper conductor of cross-section 16mm .
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Routing of the earth cable to the ground conductor within the last column of each feeder pillar
outgoing subcircuit shall be via a 100mm. PVC duct within the column foundation.
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15.20 INSTALLATION
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1 The Contractor is responsible for all liaisons, through the Engineer, with the departments
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concerned within the PWA, in respect of programming the installation and commissioning of
the complete road lighting system. He shall also ensure through the Engineer that the
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relevant departments within the PWA are at all times kept informed of the current progress of
the work. Throughout the road lighting installation works the engineering representative from
the relevant departments within the PWA, must be invited to carry out periodic inspections of
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the works. The Contractor shall ensure that his approved subcontractor programmes works
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are in the designated sequence in accordance with the approved programme. On completion
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of each phase of the works progress to the next phase will be subject to the approval of the
Engineer’s Representative and/or the relevant departments within the PWA.
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2 A qualified person having a thorough experience in road lighting and associated equipment
shall supervise the execution of all electrical work.
3 Only workmen who have had experience in the erection of road lighting shall be employed on
the work of erection.
4 Before carrying out any electrical works to existing services, authorisation must be obtained
in writing from all relevant authorities.
5 The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in
the ILE Code of Practice for Electrical Safety.
6 Where an existing installation has been extended the relevant parts of the existing system
and equipment earthing shall be inspected and tested for compliance with the IEE Wiring
Regulations.
7 A completion certificate as detailed in the IEE Wiring Regulations shall be issued following
the inspection and testing of the installation and any corrective action found necessary.
15.20.2 Temporary Lighting
1 Where the existing installation is to be disconnected during the Contract Period, temporary
lighting shall be provided. Any temporary lighting proposals must have the approval of the
PWA prior to installation.
2 At no time shall design road lighting standards be lower than those existing prior to the start
of the Contract.
3 The Engineer must approve any form of temporary lighting and associated lighting levels.
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4 Temporary lighting shall not be removed or disconnected until the permanent installation has
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been inspected and approved by the Engineer and has been energised.
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15.20.3 Removal of Existing Columns
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1 Prior to any work being undertaken the Contractor shall obtain from the relevant departments
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within the PWA a copy of the latest revised record drawing of the existing lighting network
within the contract limits. The Contractor is to identify from these records those columns
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affected by the Contract and require removal or relocating. A copy of any record obtained
shall be forwarded to the Engineer for his use.
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2 Existing columns shall be removed under supervision of the Engineer’s Representative in

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consultation with the relevant department within the PWA. Existing cables shall be
disconnected, made safe and protected to the satisfaction of the Engineer in consultation
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with the relevant departments within the PWA prior to removal of the columns.
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3 No existing road lighting shall be switched off, dismantled or removed without the prior
approval of the Engineer and the relevant departments within the PWA. Where the existing
road lighting has been removed the Contractor, to ensure safe vehicular and pedestrian
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movement within the designated area, shall provide necessary temporary lighting complete at
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his cost. Existing signs shall also be relocated at the Contractors cost to ensure compliance
with the current traffic regulations.
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4 All lamps, luminaries and fittings shall be removed before excavating around the column prior
to its removal. Tie ropes shall support the columns at all times.
5 The Contractor shall carefully excavate existing material from around the column base,
including concrete taking care not to damage any adjacent cables or services. No assembly
shall be removed until it has been fully excavated.
6 The columns shall be lifted from the foundation by means of a crane approved by the
Engineer. The foundation shall be backfilled with suitable approved material and temporarily
reinstated.
7 All columns, cables, lamps and luminaries to be removed under the Contract shall be taken
to store as directed by the Engineer and remain the property of the PWA. Where such items
are instructed to be taken to the stores of the PWA, proof of delivery should be obtained by
means of a signed receipt from the relevant departments within the PWA and witnessed by
the Engineer’s representative.
8 Existing road lighting, where it is to be relocated within the Contract, shall be carried out in
accordance with the relevant sections of the contract specifications, as if new. Prior to re-
installing all equipment it shall be inspected and any damage reported to the relevant
departments within the PWA, via the Engineer.
15.20.4 Detailed Drawing for RCC foundation
1 The foundation for the 3 metre to 12 metre lighting columns shall be in accordance with the
details provided within the Contract Documents. The reinforcement detail shall be detailed by
the Contractor based on the recommendations of the column manufacturer to meet the
column assembly design criteria detailed in paragraph 15.6.7 of this specification. Contractor
shall consider the use of augured foundations in areas where soil and lighting utility
reservation necessitate it, as per the Contract Documents.
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2 The foundation detail for the lighting columns or masts between 16 metres to 30 metres will
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be as recommended by the column manufacturer for the climatic conditions applicable to the
State of Qatar taking due consideration of the equipment to be supported. Contractor shall
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consider the use of augured foundations in areas where soil and lighting utility reservation
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necessitate it, as per the Contract Documents.
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Final configuration of the proposed foundation will be subject to the approval of the Engineer
and the PWA.
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15.20.5 Road lighting Column/Lantern Installation
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1 Road lighting columns shall be erected on pre-constructed bases offset from the
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carriageway, as defined in the contract Specification, via anchor bolt arrangement.

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2 Prior to erection of the lighting pole no bracket arm or lighting fixtures shall be mounted on
the column shaft.
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3 Only purpose made cranes with nylon slings will be accepted for the purpose of lifting the
columns onto the anchor bolts. Metal chains are not acceptable.
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4 The bottom securing nut/washer arrangement or shims shall be used to align the lighting
column vertical. The location of the base compartment door shall be agreed prior to the
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installing of the column shaft, but unless notified otherwise the door opening shall be located
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such that any operative working within the column shall face the on-coming traffic.
5 Once installed, the final alignment and verticality of the column shall be checked in two
directions at 90 degrees to each other by theodolite or other approved method. The final
verticality is to be approved by the Engineer’s Representative prior to the column bracket and
luminaire as specified being installed and commissioned.
6 The underground cables shall be terminated into the cut-out/isolator assembly mounted
within the lighting pole base compartment. An additional length of 500mm shall be allowed at
each incoming cable termination and shall remain underground for future reconnections.
7 Wiring between the terminal block in the luminaire and the components in the base of the
column or each unit shall be using high temperature 3 core, green or yellow, blue and brown,
2.5mm2 copper flexible cables to BS 6141.
8 All installation requirements described in the ILE Code of Practice Clause 11 shall apply.
9 A double insulated 6.0mm2 stranded copper earth wire with clamped tag bonded to earth lug
on column and the column door earth terminal shall be provided.
10 All cable routes shall be clear of control gear and limited to horizontal and vertical runs.
Cables entering terminals shall show no bare wire nor shall the insulation be taken into the
electrical conducting part of the terminal. All cable shall be neatly bunched together and
securely taped.
11 Terminal blocks shall be clearly marked and the wiring shall be so arranged that the
luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without
any electrical wiring disconnections.
12 After installation each lighting column shall be identified by a reference number in

accordance with the requirements of the PWA.
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15.20.6 Road lighting Feeder Pillar Installation
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1 The road lighting feeder pillar shall be erected on pre-constructed base off set to the
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carriageway, as defined in the Contract specification, via anchor bolt arrangement.
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Prior to erection no internal equipment shall be installed which could be damaged either in
transit to site or during the erection phase.
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3 The bottom securing nut/washer arrangement or shims shall be used to align the feeder pillar
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vertical.
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4 The electrical installation within the feeder pillar shall be undertaken as detailed elsewhere in
the specification.
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5 All underground cables when terminated shall allow for a minimum length of 500mm to be left
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underground to allow for future reconnections
15.20.7 Road lighting Cable Installation

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1 The installation of all cables shall be in accordance with the requirements of QCS Section 21.
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2 2
2 Excavation of Road lighting Cable trenches for cable size from 10mm to 35mm x 4 core are
to be of the following dimension:
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Depth: 600mm
Width: 500mm
3 Cable trenches shall be cleared of all stone and sharp projections and shall be drained. All
cables shall be laid on a bed of 150mm approved fine aggregate sand or quarry scalping.
Cabling to and between columns will be by means of copper stranded 4core
XLPE.SWA.PVC cable. (Size as indicated and based on the connected electrical load and
length of cable from power source) and shall be at the depth of 450mm. A layer of 150mm
dune sand or quarry scalping is to cover the cable. No joints in Cable shall be permitted.
4 LV cables laid shall be laid straight between lighting columns with an allowance for 500mm
spare underground cable adjacent to each column. Cables can be placed in the same trench
with a lateral spacing between cables of 50mm. In the event of HV cables being placed in the
same trench then there shall be a separation of at least 300mm. All cables shall have a
clearance of at least 300mm from all other services including telephone or communication
cables.
5 The Contractor shall arrange for inspection of the cable, trenches and cable installations by
the Engineer’s Representative, in conjunction with the relevant departments within the PWA
prior to backfilling.
6 All cables shall be handled, installed and terminated in accordance with the manufacturer’s
recommendations. The manufacturer’s recommended ambient temperature limitations for
the handling of cables shall be strictly adhered to.
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7 All cables, once removed from the cable drum, shall be immediately laid in position. No cable
shall remain laying on the surface for more than is practicably possible.
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8 Cabling is to be looped into each column and terminated by means of an approved lighting
column cut out.
15.20.8 Road Crossing Ducts nt

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1 Underground ducts shall be provided where cables
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(a) Cross roads or other paved areas with vehicular access.

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(b) Cross unpaved areas regularly used by vehicles.

(c) Enter buildings.
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(d) Vehicular entrances to properties.

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(e) Pass through corrosive soils or elsewhere as designated, they shall be drawn into
underground pipe ducts.
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2 A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run
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immediately after its installation. A 2m surplus shall be left at each end of each run, neatly
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coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct.
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3 Underground pipe ducts shall be heavy gauge unplasticised PVC (high impact resistant PVC,
3.6mm wall thickness) conduits with tapered sleeve or spigot and socket joints encased in
concrete as detailed in the Contract drawings and in accordance with the requirements of the
PWA.
4 All ducts shall have a nominal internal diameter of 150 mm unless designated otherwise.
5 The internal diameter of ducts used to provide cable entries into structures shall have a
space factor less than 25 %, unless otherwise designated.
6 All dual systems shall be installed so that no undue strain is placed on cables when pulled in.
Cable manufacturer’s recommendations shall be followed.
7 All underground cable ducts shall, so far as possible, be run in straight lines.
8 Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis
of the road. They shall be laid at a depth of 800mm backfilled and reinstated in accordance
with QCS.
9 Except in the case of short isolated duct runs such as road crossings, underground cable
duct runs shall terminate in suitable drawpits.
10 Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded
with concrete of grade SRC 30 as per the standard detail.
11 Ducts shall be laid so as to drain naturally towards one or both ends, where adequate
provision for drainage shall be made. Adequate precautions shall be taken to prevent the
cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of
1 in 200 shall be provided for drainage purposes.
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12 Any work carried out requiring the use of split ducts shall be carried out in such a manner as
to preserve the withdrawability of the cables concerned.
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13 Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is
liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be
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installed on a concrete bed as designated above, but without concrete surround.
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14 If two or more cables are to be installed in the same duct, the aggregate of their cross-
sectional areas shall not exceed 30 % of the cross-sectional area of the duct.
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15 All trenches excavated for the laying of cable ducts shall be completely backfilled and
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rammed before cable installation work begins.
16 Immediately following the installation of any duct run, the interior of the duct shall be
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thoroughly cleaned by twice drawing through the ducts a mandrel, once in each direction.
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Following this, the ends of each run shall be sealed with a suitable hardwood or plastic
sealing plug which shall be left in position until cable laying is about to begin.
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17 The polished hardwood mandrel shall be 300mm long having spherical ends and a diameter
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6mm less than the nominal duct diameter.

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15.20.9 Backfilling and Re-instatement

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1 All trenches and pole pit/foundations shall be backfilled, compacted and re-instated in
accordance with the QCS requirements.
15.20.10 Road lighting Cable Terminations and Testing
1 Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where
applicable, and shall be of a design appropriate to the type of cable being terminated.
2 Glands for cables with metallic inner sheaths shall incorporate a bonding connection.
3 Except where it is impracticable to do so, the cable cores shall be taken through the
terminating box directly to the terminals of the equipment, without crosses, and shall be
made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped
socket.
4 Terminations for armoured cable shall incorporate a method of rating off the armour which
ensures a permanent earth bond between the cables terminated to the satisfaction of the
Engineer. The cable armour shall be bonded to the earth terminal block in each column.
5 All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in
the appropriate colours, to indicate the disposition of the phase and neutral conductors within
them.
6 Compression glands installed externally shall be classified IP66 and be provided with close-
fitting PVC shrouds.
15.20.11 Electrical Power Supply
1 Upon the completion of the associated work, arrangements will be made via the Engineer to
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provide the electrical power to each road lighting feeder pillar based on a 415V 50Hz supply.
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Once available, and after inspection, the lighting system shall be tested prior to connection.
The Engineer shall arrange for full consultation with the relevant departments within the PWA
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during this phase of the lighting works.
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15.21 TESTING AND COMMISSIONING ON SITE
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15.21.1 General
1 In addition to the requirements of the Contract Specific Specification all testing and
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commissioning shall be carried out according to the requirements of the relevant BS , CP,
IEE regulations, or other standards and regulations as may be stated or implied in this
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Specification.
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2 Each completed system with the installation shall be tested as a whole under operating
conditions to ensure that each component functions correctly in conjunction with the rest of
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the installation.
3 The Contractor shall afford access at all times to the relevant departments within the PWA to
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enable them to inspect work during and after erection and to be present at all tests.
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15.21.2 Electrical Tests

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1 As soon as is practicable after the completion of installation the tests described below,
together with such other tests and measurements to prove compliance with the contract
requirements shall be made.
2 An insulation tester shall be used to measure the insulation resistance between each
conductor and the remaining conductors and between each conductor and the metallic
sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V.
3 The above tests shall be carried out both before and after any pressure tests and the
insulation resistance shall not be less than the figures in the appropriate BS.
4 A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix
88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable.
5 Proposals for the appropriate test in respect of other types of cable shall be submitted for
approval.
6 An earth continuity test shall be carried out to verify that the cable armouring and metal
sheath, if any, have been properly bonded to earth.
7 Phase rotation and phase correspondence shall be tested to prove that the cables have been
correctly connected.
8 Where a new cable has been jointed to an existing cable with the express permission of the
Engineer, the voltage test designated above may be carried out at a reduced voltage if the
existing cable has been in service for more than five years. In such a case the test voltage
shall be determined by applying a factor K to the value given in the appropriate British
Standard as referred to above.
9 The Contractor shall afford access at all times to the representatives of QGEWC and the
relevant departments within the PWA to enable them to inspect work during and after
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erection and to be present at all tests.
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10 Upon completion of laying and terminating underground cable runs, the Contractor, in the
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presence of the Engineer or his duly authorised representative, shall carry out pressure tests
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in accordance with relevant British Standards. The Contractor shall provide all apparatus and
labour required for such tests and within a reasonable time thereafter shall present the
Engineer with certificates of the tests.
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15.21.3 Photometric Performance Testing
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1 A certificate of Initial Lighting Performance of Installation shall be issued when tests have
been passed as follows:
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(a) The initial photometric tests shall be made after the installation has been in lighting
operation for between l00 and 150 hours
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(b) The location of test positions shall be distributed along the length of the installation and
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shall be as directed by the Engineer. All service tests throughout the testing period
shall be made at these positions.
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2 Readings shall be taken with a portable calibrated luminance meter holding a current valid
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calibration certificate. The measurements in accordance with the procedures laid down by the
CIE and shall be taken by a qualified lighting engineer who shall confirm that the lighting
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performance data as identified in the contract specification has been satisfactorily obtained.
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3 Measurement of the supply voltage at adjacent lighting columns and posts shall be taken at
the time of each test and the illumination measurement shall be adjusted for any variation
from the supply voltage value declared in the contract specification. Allowance shall be made
for the use of control gear taps if necessary immediately before the initial tests are made.
The lamps and all components of the luminaire that may affect the optical performance shall
be cleaned and correctly adjusted.
4 The Engineer shall witness all photometric testing, unless otherwise notified in writing. A
minimum of 7-days’ notice shall be given to the Engineer before testing begins. After testing
the certificates shall be submitted to the Engineer for approval. Representatives from the
relevant departments within the PWA shall be invited to witness the lighting performance
testing.
15.22 RECORD DRAWINGS
15.22.1 General
1 Within thirty days from the date of completion of the whole or any section of the lighting works
the Contractor shall provide fully detailed "as built" drawings and schedules in respect of all
sections of work completed together with all relevant operating and maintenance instructions.
The drawings shall: -
(a) Fully indicate with accurate dimensions the sizes, types and position of equipment,
cables, ducts, joints, feeder pillars etc., with particular regard for the need to accurately
locate buried cables after completion.
(b) Show the circuit arrangements for the relevant section of the road lighting installation.
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(c) Show full details, ratings and function of each item of equipment.
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(d) Include any other relevant information to ensure the safe and satisfactory operation of
the particular section of the road lighting works.
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2 The Contractor shall submit, within the time stated above, two copies of the Record Drawings
for the approval of the Engineer. Upon and after receipt of such approval the Contractor shall
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provide records in both digitised and hard copy format of reproducible transparent negative
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drawings, and two sets of prints on paper to the Engineer for his retention.
3 In addition to the foregoing, the Contractor shall provide in each feeder pillar and distribution
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unit a good quality print on paper showing the road lighting distribution line diagram of that
particular section. These prints shall be mounted on the inside of the door of each feeder
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pillar and distribution unit and shall be covered in clear plastic to prevent undue deterioration.
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4 In order to achieve accurate Record Drawings all relevant information relating to the lighting
works shall be entered on to the stated drawings and kept for immediate use once the work
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has been carried out. The marked prints shall be available for inspection at the Contractor's
site office at any reasonable time during the progress of the lighting works.
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END OF PART
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Part 16: Traffic Signals
16 TRAFIC SIGNALS ......................................................................................... 2

16.1 GENERAL ...................................................................................................... 2
16.1.1 Summary 2
16.1.2 References 2
16.1.3 Submittals 2
16.1.6 General Project/Site Conditions 4
16.1.7 Warranties 4
16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT .............................................. 4
16.2.1 General 4
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16.2.2 Identification of Equipment 5
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16.2.3 Traffic Signal Posts 5
16.2.4 Traffic Signal Gantries 5
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16.2.5 Three-Aspect Traffic Signal Heads 6
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16.2.6 Two-Aspect Pedestrian Signal Heads 7
16.2.7 Traffic Signal Controllers
16.2.8 Pedestrian Operated Push-Buttons
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16.2.9 Flexible Traffic Signal Cable 10
16.2.10 Armoured Traffic Signal Cable 10
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16.2.11 Loop Cables 11

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16.2.12 Loop Feeder Cables 11

16.2.13 Pulling Chamber Cover 11
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16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts 12

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16.2.15 General Compatibility 12

16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT ................................. 12
16.3.1 General 12
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16.3.2 Poles, Gantries and Signal Heads 12

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16.3.3 Installation of Traffic Signal Controller 13

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16.3.4 Cabling 13
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16.3.5 Circuit Protection and Earthing Requirements 14

16.3.6 Permanent Electrical Power Supply 15
16.3.7 Inductive Loops for Vehicle Detection 16
16.4 TESTING AND COMMISSIONING .............................................................. 20
16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL
EQUIPMENT ............................................................................................... 21
16.5.1 General 21
16.5.2 Operational Maintenance 21
16.5.3 Emergency Maintenance 23
16.5.4 Contractor’s Vehicles 23
16.5.5 Contractor’s Equipment 23
16 TRAFIC SIGNALS
16.1 GENERAL
16.1.1 Summary
1 This Part includes the provision of traffic signal equipment and related street furniture at
controlled roadway junctions and pedestrian crossings.
2 Related Sections
Section 1 General
Section 5 Concrete
Section 9 Mechanical and Electrical Equipment
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Section 10 Instrumentation, Control and Automation
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Section 21 Electrical Works
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16.1.2 References
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The following standards are referred to on this Part:
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BS 1361......................Cartridge fuses for a..c circuits in domestic and similar premises
BS 381C .....................Specifications for colours for identifications
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BS 5493......................Code of practice for protective coatings of iron and steel structures
against corrosion.
BS 7430......................Code of practice and regulations for earthing
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BS 7671......................Requirements for electrical installations

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BS 88..........................Cartridge fuses for voltages up to and including 1000 Vac and 150 Vac
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BS EN 1011................Process of arc welding carbon and carbon manganese steels

BS EN 12368..............Road traffic signals
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BS EN 13108..............Fine cold asphalt

BS EN 60529..............Degrees of protection provided by enclosures
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BS EN ISO 146 ..........Hot dip galvanised coatings on iron and steel articles
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AASHTO Standard specification for supports for highway signs, luminaires, traffic signals
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DIN 40050 ..................Enclosures for electrical equipment

DIN 6163 Part 5..........Diffusion lenses for traffic signals
QGEWC (E) Regulations for Electrical Installations

QGEWC (E) Regulations for Protective Multiple Earthing
16.1.3 Submittals
1 The Contractor shall submit to the engineer for approval shop drawings for each type of
signal pole, gantry and mounting frame for signal heads to be provided under the Contract
along with structural calculations. The drawings shall show materials specification and
finishes for each component proposed for use. All weld types and sizes shall be identified on
the shop drawings.
2 The Contractor shall submit to the engineer for approval design calculations for the proposed
signal poles and gantries. The design calculations shall be carried out in accordance with the
AASHTO Standard specification for supports for highway signs, luminaires, and traffic signals
3 The Contractor shall propose a design for the foundations for each type of signal pole and
gantry and shall submit design calculations and drawings to the Engineer for approval.
4 The Contractor shall submit to the engineer for approval a schematic wiring diagram for all
the installations. The Contractor shall also submit a wiring layout drawing for the cable loops
and the cross-sectional details of the cut in the road surface.
1 Contractors for the works shall be experienced specialists in the field of traffic control
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systems with a minimum of 5 years experience of the installation, commissioning and testing
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of such systems in a similar environment.
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2 The Contractor shall submit a technical submission for the proposed subcontractor giving
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details of previous installations date installed, client, technical data for proposed materials,
and experience record of proposed installation staff, supervisors and management.
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3 Installation of traffic signal equipment shall only be conducted by approved specialist
subcontractors. The specialist subcontractors shall be approved by the PWA.
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4 The performance and design requirements work shall be in compliance with QGEWC
Regulations for Electrical Installations.
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5 All equipment supplied shall, in general, conform to the same style, colours and functions as
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that already in place in Qatar. The supplier may be required to provide, at his own expense,
samples of his proposed equipment.
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6 All equipment and installation shall be in accordance with the latest edition of the Qatar
Traffic Manual. For all signalled intersections and pedestrian signal control crossings the
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timing sequence of signals displayed to drivers during phases shall be as per information
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given by the PWA and/or Traffic Police.

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1 Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
acceptance test in his workshop. The programmed and internally complete controller shall
be connected to a labelled light board capable of simulating all traffic signal aspects
controlled by that particular controller. The Contractor shall ensure that all equipment and
devices are available to show that the controller fully complies with operational requirements.
The factory acceptance test shall consist of the following checks:
(a) visual check of internal wiring and controller assembly

(b) operation of green conflict monitor
(c) intergreen times
(d) group times
(e) detector logic (where applicable)
(f) stage to stage change logic
(g) lamp switching.
2 The Contractor shall be responsible for the delivery of all items to the project site or to any
site as required by the Engineer.
16.1.6 General Project/Site Conditions
1 All equipment and associated components shall be designed and suitably rated to ensure
proper maintenance, continuous trouble free service under the prevailing climatic conditions.
All equipment and installation shall operate satisfactorily in a temperature range of 0 C to
+55 C and under humidity conditions ranging from 10 % to 100 %.
16.1.7 Warranties
1 All warranties and guarantees for traffic signal equipment shall commence from the day of
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commissioning. The warranty period shall be that as designated by the manufacturer but
shall in any case not be less than 400 days
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16.2 SUPPLY OF TRAFFIC SIGNAL EQUIPMENT
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16.2.1 General
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It shall be the Contractor’s responsibility to ensure that all equipment supplied is approved.
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The Engineer will advise on approved suppliers.
2 It shall be the Contractor’s responsibility to honour the designated warranty periods..

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3 The Contractor, shall make himself aware of any lead times required for delivery of
equipment and programme his works accordingly. It shall be the Contractor’s responsibility to
ensure that equipment is available as needed, any delays to works resulting from the
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unavailability of equipment shall be deemed to be the responsibility of the Contractor.

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4 The Contractor shall be responsible for the correct delivery, storage and handling and
storage of all equipment up to the time it is commissioned.
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5 All equipment shall comprise of units of a type that have been used successfully in other
installations in a similar environment, from a minimum period of six months and shall be
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subject to approval of the engineer. Particular attention shall be given in the selection and
design of equipment and components to the exclusion of water, moisture and dust.
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6 Components and materials that may perish and deteriorate in the climatic conditions of Qatar
shall be avoided. All equipment shall be so constructed as similar units that shall be readily
available and completely interchangeable both mechanically and electrically.
7 The location layout of each installation and the number of phases and stages for each traffic
controller shall be as designated Controllers shall provide the signal sequences and phasing
designated for each installation.
8 The structural design and traffic signal posts and traffic signal gantries shall be in accordance
with provisions of AASHTO standard specification, Supports for Highway Signs, Luminaires,
Traffic Signals, or an approved alternative.
16.2.2 Identification of Equipment
1 The Contractor shall mark or clearly label all modules, units and main parts of a system with
a functional code or title, type number, serial number as approved by the Engineer.
2 Marking shall maintain legibility throughout the life of the equipment under the prevailing
environmental conditions.
3 The labelling system shall comply with the GIS system (as defined in the data dictionary)
used by the Government of Qatar and the PWA.
16.2.3 Traffic Signal Posts
1 Traffic signal poles shall be of the tubular steel type with a flanged base, having an internal
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electrical termination point accessible through a lockable inspection window. The supply of a
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traffic signal pole shall include; holding down bolts, nuts, washers and shims required for
erection; pole; terminal block; locking cover for inspection window complete with three sets of
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keys; all grommets; glands and cable anchor points.
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2 Traffic signal poles shall have dimensions conforming to those given in the contract
Drawings.
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3 The traffic signal poles shall be of mild steel construction. Corrosion protection shall be
through the use of a hot dipped galvanised coating conforming to the requirements of British
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Standard BS 5493 and BS EN ISO 1461, depth of galvanised coating shall be 85 microns.
All welded connections shall conform to British Standard BS EN 1011.
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4 The termination point shall consist of a terminal block positioned internally within the traffic
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signal pole. The terminal block shall be fully accessible through a lockable inspection
window. The terminal block shall be securely fixed to the traffic signal pole.
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5 The terminal block shall be electrically isolated from the traffic signal pole and shall have a
minimum capacity of 2 x 20 No. connectors. Each connector shall have a minimum rated
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capacity of 100 watts at 240 volts.

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6 The connectors on the terminal block shall be in compliance with the requirements of the
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QGEWC.
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7 The traffic signal pole shall have the facility to secure incoming cables at a point prior to them
being connected to the terminal block
8 The traffic signal pole shall be fitted with an electrical earthing stud, such that at least four
earth connections can be made to it.
16.2.4 Traffic Signal Gantries
1 Traffic signal gantries shall be of the tubular steel type with a flanged base, having an internal
electrical termination point accessible through a lockable inspection window. The supply of a
traffic signal gantry shall include: holding down bolts, nuts, washers and shims required for
erection; pole caps; terminal block; locking cover for inspection window complete with three
set of keys; all grommets, glands and cable anchor points. Traffic signal gantry shall be
styled in accordance with Contract Drawings.
2 The traffic signal gantries shall have minimum dimension conforming to those given in the
Drawings. The design of the gantries is open to submission by the supplier.
3 The supplier shall provide full details of the materials used and the method of construction
employed when quoting for this item, this shall include workshop fabrication drawings,
material specifications and calculations pertaining to the structural design of the gantry. The
gantry shall be capable of supporting three aspect traffic signal heads, each having a total
weight of 25 kg, inclusive of mountings. The number and position of heads are to be as
designated.
4 With regard to termination points, cable anchor points and earthing points, these shall be as
specified in Section 6 Part12 of this Specification
5 The supplier shall furnish full details of the foundation requirements for his proposed gantry,
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this shall include details of dimensions, reinforcement, quality of concrete and fixings.
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Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanized to BS EN ISO 1461.
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6 The gantry and foundation design shall be such that the gantry is completely detachable from
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the foundation, should this be required.
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The gantry shall have a system such that it can be adjusted subsequent to installation, to
allow for leveling and turning.
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8 The supplier shall furnish full details of the proposed foundation for his proposed gantry, this
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shall include details of dimensions, reinforcement, quality of concrete and fixings. The gantry
and foundation design shall be such that the gantry is completely detachable from the
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foundation, should this be required. Anchor bolts shall be Grade 8.8 and shall be hot-dip
galvanised to BS EN ISO 1461. The gantry shall have a system such that it can be adjusted
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subsequent to installation, to allow for levelling and truing.

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9 The electrical termination point shall consist of a terminal block positioned internally within
the gantry. The terminal block shall be fully accessible through a lockable inspection window.
The terminal block shall be securely fixed to the gantry.
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16.2.5 Three-Aspect Traffic Signal Heads

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1 Three-aspect traffic signal head dimensions shall be as designated. The Contractor shall
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submit drawings of the proposed units.
2 Signal heads shall comprise of a polycarbonate body containing three traffic signal aspects,
coloured red, amber and green and shall include:
(a) lamps
(b) reflectors
(c) lenses
(d) transformers
(e) visors
(f) anti-phantom devices (if designated)
(g) brackets, frames and all fixtures and fittings required for mounting
(h) backing board.
3 Signal heads shall be constructed, in as far as is possible, out of high quality polycarbonate
plastic. Any metal fittings shall be suitably protected against corrosion.
4 The design and construction of signal heads shall allow for all of the following features:
(a) hinged lens panels to allow quick access to the lamps

(b) flexible, detachable visors
(c) easily adjustable mounting system
(d) capability of internally fitting optical arrow mask.
5 The signal heads shall use, for each aspect, a 10 volt halogen lamp of type SIG 64015/1 -
50W or SIG 64015 - 50W. The lamp holder and connectors shall be compatible with the type
of lamp used. The lamps shall conform to BS EN 12368. The supply voltage to the signal
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head shall be 240 volts ( 5 %) and shall be converted to the lamp voltage by the use of a
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standard design transformer (El Type). Each aspect shall have an individual transformer,
these transformers shall be fitted with noise suppression equipment. The transformers will be
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required to operate in ambient temperatures up to 60° C. The transformers shall have a
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minimum operational life of five years with an effective switch-on ratio of 3300: 4380.
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Signal heads shall be capable of being mounted on the traffic signal pole or gantry as
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designated or, in the case of traffic signal gantry, as may be proposed by the Contractor.
The mounting system used shall be such that no predrilling or permanent attachment of
brackets to the signal pole or gantry is required. The mounting system shall be such that the
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signal head shall be capable of being adjusted through an arc of 30 degrees about its vertical
axis. It shall be possible to mount two three-aspect traffic signal heads side by side on a
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single pole such that the vertical faces being presented to oncoming traffic of each head
remain in the same plane. It shall be possible to mount the signal heads asymmetrical from
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the centreline of the pole. The signal head shall be rendered splash proof by means of an
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lP54 enclosure. The item description covering signal heads shall include, where necessary,
extra mounting brackets to enable the above facilities.
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7 The optical reflector shall be made of a high grade aluminium, mirror finished. Diffusion
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lenses shall be constructed with an internal cobweb pattern and shall be coloured red, amber
or green as defined by the colour limits laid down in the DIN Standard DIN 6163 Part 5.
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16.2.6 Two-Aspect Pedestrian Signal Heads

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1 Two-aspect pedestrian signal heads shall have the designated dimensions. The Contractor
shall submit drawings of the proposed units.
2 Signal heads shall comprise of a polycarbonate body containing two pedestrian signal
aspects, coloured red and green and shall include:
(a) lamps
(b) reflectors
(c) lenses
(d) transformers
(e) visors
(f) anti-phantom devices (if designated)
(g) brackets, frames and all fixtures and fittings required to mount the signal head.
3 The material, electrical and mounting requirements for the signal head shall be the same as
the requirements for the three aspect traffic signal head.
4 The optical requirements for the signal head shall be the same as the requirements for the
three aspect traffic signal head with the additional requirement that each aspect of each two
aspect pedestrian signal head be supplied with a 'Walking Man' and 'Stopping Man' optical
mask.
16.2.7 Traffic Signal Controllers
1 Traffic signal controllers shall be microprocessor based and capable of meeting all the
designated requirements. The Contractor shall submit drawings of the proposed units.
2 Supply shall include:
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(a) basic control hardware including relays housings and cabinets
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(b) all required additional modules and circuits
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(c) all internal wiring
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(d) all detector modules and control circuits
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plates, fixings and fastenings, glands, seals and clips.
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3 The controller shall be provided with the following operational modes:
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(a) computer control

(b) standby co-ordinated
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(c) local mode with multi-plan operation

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(d) flashing
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(e) manual mode

(f) signal on/off mode.
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4 Means will be provided within the controller housing to select and to test each of these
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modes of operation.
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5 For pedestrian crossings the controller shall be capable of showing a green flashing man
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before the end of each pedestrian phase.
6 All controllers shall include a dimming feature.
7 Controllers shall be of a manufacturers type approved by the PWA and/or Traffic Police.
8 All equipment supplied shall be compatible with the existing traffic signal controllers in use in
the state of Qatar.
9 Where the supplier cannot provide evidence of his equipment having been previously
successfully used with the above traffic signal controllers, he shall be required to
demonstrate, at his own expense, the compatibility of his equipment.
10 Traffic signal controllers shall be programmed as designated and as agreed with the
Engineer. It shall be the Contractor’s responsibility to provide competent personnel to
programme the controller.
11 Each controller shall be supplied with full documentation which shall include :
(a) wiring diagrams

(b) timing charts
(c) intergreen tables
(d) stage diagrams
(e) any other relevant information relating to the operation.
Three copies of the documentation shall be supplied with each controller.

12 The controller shall be housed in the cabinet of sufficient size to accommodate the controller
and all other associated equipment and shall provide easy access for maintenance and test
purposes. The controller and associated equipment shall be arranged within the cabinet so
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that they will not interfere with the entry and exit cables. The cabinet to house signal
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controllers shall be constructed of aluminium sheet of thickness 3 mm in accordance with BS
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EN 12368 or with non-metallic materials where the properties for abrasion resistance,
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exposure to the elements are equal or better than aluminium cabinet. Cabinets shall be
painted to a colour and specification agreed by the Engineer. The cabinet shall be
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weatherproof, rain proof and dust proof and be able to maintain proper operation of
equipment. The Contractor shall construct a suitable foundation for the cabinet. and it shall
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allow for the entry and exit of all cables. The cabinet shall be secured to the foundation by
anchor bolts.
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13 The traffic signal controller shall be micro-processor based and capable of meeting all the
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requirements of the operational Specification and any further requirements as specified by

the Engineer. The supply of a traffic signal controller shall include for: the basic control
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hardware including relays housings and cabinets, all additional modules and circuits required
to meet the operational Specification, all internal wiring, all detector modules and control
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circuits, plates fixings and fastenings glands, seals and clips.
14 Traffic signal controllers shall be of an approved type and supplied by an approved

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manufacturer taken from the most recent list prepared by the Public Works Authority.
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15 Traffic signal controllers shall be programmed according to the operational Specification and
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as agreed with the Engineer. It shall be the Contractor’s responsibility to provide competent
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personnel to programme the controller.
16 The traffic signal controller shall also have the following capabilities:
(a) To give a flashing red pedestrian man before switching to a red man at the end of
pedestrian cycle.
(b) The controller shall include a timing feature.
(c) The controller shall support two power supply inputs coming from two different
substations. The purpose is to continuously operate the controller in case of power
failure on one substation by automatically transferring to the other power supply input.
(d) The controller shall be made to ensure that the dual power supply input is stabilized at
240 volts.
(e) The controller can be operated manually.
(f) The controller shall be capable of providing flashing green before switching to
yellow/amber at the end of vehicle green phase
(g) The controller shall be capable of providing continuous flashing yellow/amber in the
channelized island.
17 Each traffic signal controller shall be fully documented, this shall include: wiring diagrams,
timing charts, intergreen tables, stage, diagram and any other relevant information relating to
the operation. Three (3) No. copies of the documentation shall be supplied with each
controller.
16.2.8 Pedestrian Operated Push-Buttons
1 Pedestrian operated push-buttons shall comply with the requirements and regulations of the
QGEWC.
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2 The push-button shall include traffic signs as per the Qatar Traffic Control Manual either as
an integral part, or be mounted separately on the traffic signal pole or gantry.
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3 Push-buttons shall comprise of a metal or plastic body containing a push-button switch and
an illuminated text panel in Arabic and English.
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The unit shall have a light that provides confirmation after a pedestrian has pushed the
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button.
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5 The dimensions and position of the push-buttons shall be proposed by the supplier and
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6 Push-buttons shall be constructed of metal or high grade plastics.

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16.2.9 Flexible Traffic Signal Cable

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1 Flexible traffic signal cable shall comprise of four cored, PVC coated, internal core PVC
coated, cable. The cable shall be PVC sheathed wiring, catalogue description being NYM-J,
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page 2/3 or equivalent.

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2 The cable shall be of a rated voltage and current carrying capacity suitable for the proposed
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cable runs. The Contractor shall submit calculations showing the voltage drop for the cable.
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3 Cable shall be supplied in 500 metre lengths and wound onto a suitable cable drum.
4 Cable shall have a minimum cross-section area of the conductor in each core of 1.5 mm2
and the overall diameter of the cable shall be 11 mm. The individual core may be either solid
or stranded. Each core shall be uniquely identifiable by coloured PVC sheathing.
16.2.10 Armoured Traffic Signal Cable
1 Armoured traffic signal cable shall comprise of a multi-cored (number of cores as specified),
PVC coated, copper wire armoured, internal core PVC coated, cable. Catalogue description
being, PVC-CWA-PVC or equivalent.
2 Cable shall be supplied in 500 m lengths, wound onto a suitable cable drum.
3 Cable may be supplied in three sizes, 7 core, 12 core or 19 core. The minimum area of the
conductor in each core shall be 1.5 mm2. The individual cores may be either solid or
stranded. Each individual core shall be uniquely identifiably by either having a uniquely
coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.
16.2.11 Loop Cables
1 Loop cables shall consist of a heat resistant coated core cable. Loop feeder cables shall
comprise of a communication type cable, PVC coated having six pair of individually coated
cores. The Loop shall be manufactured by Never Fail Loop Systems, USA (local
representative Traffic Tech (Gulf), P.O. Box 9377, Telephone Number 4621814) or similar
approved.
2 Loops shall be constructed from polypropylene conduit with 9.5mm inside diameter and
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16mm outside diameter. Conduit shall be filled with hot rubberised asphalt which allows the
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loop to remain flexible once cooled to prevent incursion of moisture and set the turns of wire
firmly in place. Loops shall have 127mm expansion/contraction joints at intervals along the
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loop to allow for movement. Each expansion/contraction joint shall have a 229mm long
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schedule 80 polypropylene cover slide to be placed over the joint.
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Lead-in wires shall be encased in a non-conductive 2250 psi flex hose constructed with a
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seamless extruded polyester fiber braid reinforcement and a non-conductive, seamless
extruded urethane non-perforated jacket. Fill lead-in hose completely with hot rubberised
asphalt. Twist wires in all lead-ins with a minimum of three turns per 305 mm for the entire
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length of the lead-in. Attach lead-ins to loop heads with a sch. 80 CVPC tee.
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4 Loop cable shall have one individual core, the conductor of which shall have a cross-
sectional area of 1.5 mm2. The loop cable such that the coating is able to withstand direct
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application of temperatures up to 175 °C.

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16.2.12 Loop Feeder Cables

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1 Loop feeder cable shall have six pairs of individual cores, each of which having a conductor
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of cross-sectional area of 0.6mm2. Each individual core shall be uniquely identifiable by

either, having a uniquely coloured PVC-U sheathing or by its PVC-U sheathing having
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unique, repetitive marking.

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2 The use of alternative types of cable may be permitted with the express written permission of
the Engineer.
3 Each individual core shall be uniquely identifiable by either having a uniquely coloured PVC
sheathing or by its PVC sheathing having a unique, repetitive marking.
16.2.13 Pulling Chamber Cover
1 Pulling chamber covers shall be of ductile iron.
2 The pulling chamber covers shall have a square opening of the dimensions shown on the
project drawings.
3 The pulling chamber covers shall be inscribed with wording to identify the type of service and
the system reference. The exact wording shall be to the approval of the Engineer.
16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts
1 Unplasticised Polyvinyl Chloride shall be supplied in two different sizes, 2 inches diameter or
4 inches diameter (50mm or 100mm). The colour shall be dark gray. The PVC-U shall be
either encased burial type or direct burial type. Catalogue description being, PVC-U
Electrical Conduit & Tubing and Utility Duct, NEMA TC-6 or NEMA TC-8 or equivalent.
2 Unplasticised polyvinyl chloride ducts shall be supplied in 6 metre lengths with solvent weld
socket on one end. The minimum wall thickness shall be 1.52 mm for 2 inches diameter and
2.08 mm for 4 inches diameter.
16.2.15 General Compatibility
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1 All equipment supplied shall, in general, conform to the same style, colours and functions as
that already in place in Qatar. The supplier may be required to provide at his own expense,
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samples of his proposed equipment. These samples shall become the property of the PWA,
whether or not an order is placed.
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2 All equipment supplied shall be compatible with the approved traffic signal controllers and
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supplied by an approved manufacturer according to the most recent approved list of the
PWA.
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3 Where the supplier cannot provide evidence of his equipment have been previously used
successfully with the above mentioned traffic signal controller, he shall be required to
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demonstrate, at his own expense, the compatibility of his equipment.

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16.3 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT

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16.3.1 General
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1 It shall be the Contractor’s responsibility to ensure that all traffic signal installation work is
conducted by skilled, competent personnel.
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2 The Engineers approval of any subcontractor or individual personnel in no way relieves the
Contractor of his responsibility to ensure that traffic signal equipment is correctly installed.
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3 The Engineer shall reserve the right to inspect and approve all installation practices.
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4 Installation of traffic signal equipment shall only be conducted by approved companies taken
from the most recent list prepared by the PWA.
16.3.2 Poles, Gantries and Signal Heads
1 Signal posts and gantries shall be installed onto their prepared foundations, using two
levelling nuts or an appropriate fixing method approved by the Engineer. The pole or gantry
shall be plumbed square, irrespective of the orientation of surrounding features.
2 The Contractor shall take every precaution to prevent damage to the pole or gantry's
protective coating, during installation. Where the protection is damaged or breached the
Contractor shall take immediate action to make repairs.
3 Where designated, posts and gantries where necessary shall be painted with an approved
paint, colour grey (BS 381C) before installation of signal heads and push-buttons..
4 Signal heads and push-buttons shall be installed as shown on the contract drawings. Final
positioning and fixing shall not be undertaken without the Engineer’s approval.
5 Signal heads, once fixed, shall be covered with an opaque protective material such that it is
clear to motorists that the signals are not in operation.
16.3.3 Installation of Traffic Signal Controller
1 The Contractor shall install the controller housing in the position defined by the Engineer. The
Contractor shall ensure that the housing is positioned so that when the access doors are
opened to their fullest extent they will not obstruct the sidewalk or cause a danger in any way
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to members of the public. The housing shall not be positioned adjacent to the kerb as to
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render it liable to damage by vehicles or so that the safety of persons working on the
controller is not endangered.
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2 The Contractor shall organise the connection of the electricity supply to the controller housing
and any other peripheral equipment requiring an electricity supply by direct liaison with the
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QGEWC (E) Consumer Section. The Contractor shall ensure that the power supply is
contained within its own separate duct, up to the point at which it enters the controller
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housing. The electrical supply shall at no point share the same ducts or chambers as the
traffic signal cabling. The Contractor, where necessary, shall be responsible for providing any
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housings required for QGEWC apparatus. Where a separate housing is required it shall be
positioned directly adjacent to the controller housing.
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3 The Contractor shall endeavour to complete as much of the internal wiring of the controller as
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possible inside his workshop, such that on-site work within the controller housing are kept to
a minimum. All external cables terminating within the controller shall be clearly labelled as to
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their function, destination and nominal voltage. These cables shall, on entering the controller
housing, be clamped and supported such that any stress or strain on the cables themselves
shall not be transmitted to the controllers internal components. Spare or redundant cables
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entering the controller housing are to be terminated in such a fashion that they do not
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interfere in any way with access to the controllers internal components. The conductors of
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these cables are to be electrically isolated and sealed against the ingress of moisture.
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4 It shall be the Contractor’s responsibility to provide all competent personnel and specialist
equipment to enable the controller to be programmed.
16.3.4 Cabling
1 The Contractor shall install all cables in the ducts as designated. He shall take all reasonable
care to ensure that no undue stress or strain is placed on the cable during installation and
shall adhere to the cable manufacturer’s published data with regard to allowable minimum
radius of curvature. The Contractor shall ensure that duct drawstrings remain in place
subsequent to cable installation.
2 A single dedicated cable shall service each individual traffic signal pole. This cable shall be of
the designated size and shall have a minimum of 10 % spare capacity. On entering the signal
pole the cable shall be firmly anchored to the pole. At least 3 m of spare cable shall be
allowed for within the signal pole, over and above that length which is required to reach the
termination block.
3 Spare or redundant cores within the cable shall be terminated at the termination block and
labelled 'Spare'. The core acting as earth protection shall be connected directly to the body
of the signal pole by means of the pole’s earthing stud. The cable armouring shall not be
used as the protective earth conductor.
4 With the exception of loop cable to loop feeder cable connections, the jointing of cables shall
not be permitted. Where jointing of the cables is permitted, this shall be undertaken using a
suitable jointing kit of an approved type which allows the integrity of the protective earth
conductors to be maintained. Loop cable to loop feeder cable joints shall only be located
within an access chamber.
16.3.5 Circuit Protection and Earthing Requirements
1 The Contractor shall provide protection against dangerous earth-leakage currents by the use
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of fuses or excess-current circuit breakers compliant with the QGEWC (E) Regulations for
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Electrical Installations. The Contractor shall ensure that all installations shall be such as to
allow for the operation of the protective devices to operate upon the occurrence of a fault
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within the time period specified for fixed equipment installations and that all non-current
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carrying metallic parts shall be connected to the earth terminal in such a manner as to ensure
that a hazardous voltage cannot exist on exposed conductive metalwork. All cabinets, posts
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and other metal hardware comprised by the traffic signalling equipment shall be bonded via
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protective conductors to the main earth terminal with an earthing conductor to the main
terminal by a protective conductor.
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2 The main earthing terminal or bar shall comply with QGEWC (E) Regulations for Electrical
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installation and shall be connected to the earthing point provided by the QGEWC (E) with a
copper earthing conductor in accordance with the Regulations. It shall have a minimum
cross-sectional area of 6.00 mm2 and shall be green/yellow stripe coded. The earthing
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conductor is defined as a protected conductor connecting a main earthing terminal or bar of

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an installation to an earth electrode of other means of earthing. Where a residual current

circuit breaker is used, the cross sectional area of the earthing conductor shall comply with
the requirements of QGEWC (E) Regulations.
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3 The connection to metalwork shall be made internally to a secure terminal on a part of the
enclosure which is a permanent fixture. The terminal shall be constructed of a material which
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will minimise chemical corrosion resulting from contact with the protective conductor or other
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metal part. Conductor terminations shall be by the use of soldered or crimped connectors or
screwed terminations, or other approved methods.
4 Earth and other protective conductors shall be selected and installed so that they comply with
the QGEWC (E) Regulations for Electrical Installations, the BS 7430, BS 7671 and the
Regulations for Protective Multiple Earthing where appropriate. All protective conductors
shall be colour coded green/yellow stripe. Where protective conductor is part of a multicore
cable and a green/yellow stripe colour coded core is not available, the Contractor shall
ensure that the protective conductor is adequately identified. Each cable shall enter the
controller housing via a stuffing gland in the gas plinth gland plate. The stuffing gland shall be
so designed as to prevent the diffusion of gas and support the cable. The earth stud of the
cable terminator shall be correctly bonded to the earth bar in accordance with the QGEWC
(E) Regulations, using a 6.00 mm2 conductor (2.50 mm2 for loop feeder cables).
5 The earthing requirements at the head of each traffic signal pole shall be as follows:
(a) the earth terminal of the gland, shall be connected to the earth terminal of the pole
with a protective earth conductor correctly terminated with crimp connectors and
having a minimum cross-sectional area of 6.00 mm2
(b) the protective conductors from each signal head, pedestrian head, push-button unit or
other equipment shall be connected together at the head of each pole and connected
to the earth terminal in the controller housing by means of one dedicated core of the
armoured signal cable servicing that pole
(c) the earth connection at the head of the pole specified in (b) above, shall be connected
to the earth stud of the pole with a bonding conductor having a minimum area of
6.0 mm2 and by means of a crimped connector, or similar
(d) push-button units fixed to a signal pole shall be earthed to the earth stud of the pole
with a separate protective conductor terminated with crimp connectors and having a
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minimum cross-sectional area of 6.00 mm2
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(e) There shall be electrical connections by means of conductors having a copper
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equipment cross-sectional area of not less than 6.00 mm2 between the earthing
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terminal and all metal structures, metal pipes and other metalwork (not being
metalwork forming part of a telegraphic, telephone or signalling circuit) which
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are, or may reasonably be expected to become, in electrical contact with the
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general mass of earth
(ii) are so situated that simultaneous contact may reasonably be expected to be
made by any person with such structures, pipes or other metalwork (or any
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metalwork in electrical contact therewith).

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These connections shall be made as near as practicable to locations where users or

maintenance staff approach the facility.
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16.3.6 Permanent Electrical Power Supply

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1 The Contractor shall be responsible for liaison with QGEWC (E) to provide a power supply to
the traffic signal controller and shall be responsible for all works required to provide this
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supply.
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2 The electricity supply shall be 240 V AC 50 Hz single phase.

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3 The Contractor shall organise, with the approval of QGEWC (E), one of the following earthing
systems:
(a) TN-S System. Where QGEWC (E) will provide an earthing point which affords a
continuous metallic return path to the earth of the supply system. The Contractor’s
earthing conductor shall be connected to this point
(b) TN-C-S System (PME). Where QGEWC (E) will provide a combined neutral earth
supply. The earthing Contractor’s earthing terminal and a lead from the earth terminal
shall be left available for the QGEWC (E) to connect to the incoming supply. A similar
neutral conductor lead shall also be left available for the same purpose
(c) TT System. Where a means of earthing will not be provided by the QGEWC (E) the
earthing terminal will be connected to an effective earth electrode compliant with the
QGEWC (E) Regulations for Electrical installations. Where the TT System is provided
by the QGEWC (E) the Contractor shall install an earth leakage circuit breaker to
comply with the QGEWC (E) Regulations.
4 The Contractor shall ensure that the equipment complies in all respects with the regulations
and requirements of the QGEWC (E).
5 The Contractor shall be responsible for all cable laying and jointing.
6 It shall be the responsibility of the Contractor to inform the Engineer of the earliest date when
he will be ready for the QGEWC (E) to make the service connections.
7 The Contractor shall supply the equipment to be terminated to the QGEWC (E) service with
phase and neutral conductors of not less than 4 mm2 and earthing conductor of not less than
6 mm2. The QGEWC (E), shall connect the controller conductors and earth conductor to the
terminal provided by the QGEWC (E).
8 The QGEWC (E) cut-out shall incorporate a high breaking capacity fuse carrier and fuse to
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BS 88 or BS 1361 of the correct rating. The rating shall be specified by the Contractor to
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comply with the type requirements of the QGEWC (E) Regulations. The maximum
permissible earth fault loop impedance shall be those stated in the QGEWC (E) Regulations.
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16.3.7 Inductive Loops for Vehicle Detection
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Slot cutting shall be carried out by a specialist subcontractor. The Contractor shall be
responsible for marking out all slot configurations and shall supervise the work of the
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subcontractor. The slot cutting subcontractor shall make arrangements to provide an
adequate water supply to enable him to carry out the necessary works. The approximate
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position of inductive loops and route of feeder cables will be as designated. The Contractor
shall specify the loop configurations at each site, the detailed layout of individual loops and
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the number of turns per loop. This information shall be supplied to the Engineer. When loop
configurations are specified by the Engineer, such information as required will be supplied to
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the Contractor. In order to obtain a high standard of installation, the Contractor's staff and
subcontractors shall be fully briefed by the Contractor and given written instructions
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describing the technical requirements of this specification and method of installation. This
shall cover depth and preparation of slots, backfilling, jointing, ducting under kerbs, earthing
and commissioning of equipment.
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2 Subsurface detector housings for loop detection equipment are not acceptable to the
Engineer. Detector housings shall be positioned so as to reduce the possibility of damage in
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the event of a road traffic accident and shall not present an obstruction or visual intrusion. In
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cases of doubt, the advice of the Engineer shall be sought. Positions of detector housings
shall be to the approval of the Engineer. Where a remote detector housing is used, each one
shall be connected to the controller by 'Twinflex' cable. The cable will be ducted to the
controller unless the Engineer's agreement is obtained to cutting a slot in the carriageway.
Voltages on this cable shall not exceed 50 V AC or 120 V DC whether between conductors or
to earth. The Contractor shall provide two sets of keys to all equipment housing supplied as
initial issue. The Contractor shall be responsible for removing all surplus materials from site
at the completion of the works.
3 The cable specified may in exceptional circumstances be replace with an armoured multicore
cable (i.e.. triple vehicle extensions with speed discrimination) double vehicle extensions with
speed assessment. The cable specified shall be terminated at the controller with a cable
gland or castellated bar approved by the Engineer. The gland shall be bonded to the earth
point using a 4 mm2 flexible earthing cable terminated with crimp connection tags. The
remote end of the cable shall be connected to the plate and 4 mm2 flexible earthing cable
terminated with crimp connection tags or by other means approved by the Engineer. In
addition one core of the armoured cable shall be used as an earth continuity conductor and
shall be bonded to the earth point on the controller and to both the equipment earth and the
metalwork of the housing at the remote end of the cable. The cable specified shall be
provided with a minimum of 25 percent spare conductor capacity (armoured and non-
armoured multicore cables only).
4 The detector shall operate satisfactorily with a feeder up to 100 metres in length. The feeder
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is defined as the cable between the loop tails and the detector housing. Where adjustments
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are required to sensitivity and presence time, these shall be made during initial setting-up and
no further adjustments shall be necessary. The equipment, including loop and feeder, shall
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operate correctly within all carriageways of reasonable condition without any reduction in
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performance as follows:
(a) air temperature (-10°C to 60°C)

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(b) relative humidity up to 100 % (non-condensing)
(c) carriageway flooded under 1 cm water, or dry
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(d) carriageway subjected to continued heavy use by buses and heavy goods vehicles
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(e) sidewalk and kerbs subjected to misuse by vehicles

(f) feeder assumed to be buried in soil or sand which may be dry or wet
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(g) the detector shall not operate from electrical noise pick-up on the loop or feeders.
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5 Slot-cutting operations shall not be conducted in wet weather. Wet weather to be defined as
such conditions where the Engineer considers it would be unsafe to carry out slot cutting
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operations. Slots shall be cut using a motorised machine fitted with a diamond saw blade.
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The layout of the loop configuration shall avoid areas of poor reinstatement in the road
surface caused by other roadworks or works. Slots shall be cut at least one metre from any
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such disturbance. Slots shall be cut at least one metre from any ferrous objects such as
manhole covers. In concrete road surface, the Contractor shall not cut slots less than 1.5
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metres from transverse joints between adjacent concrete sections. The depth of loop slots
shall be (50 + 7.0 n) mm with a tolerance of + 10.0 mm / - 0.0 mm. In concrete surfaces the
depth shall be (25 + 7.0 n) mm with a tolerance of + 5.0 mm / - 0.0 mm where 'n' is the
number of cables and the first figure is the minimum depth of cover. The depth of each slot
shall be checked with a depth gauge along the whole length of the slot. The Contractor shall
ensure that there are no irregularities in the base of the slot. Where an angle more acute
than 13 degrees in formed at the junction of two adjacent loop slots, then the slot junction
shall be truncated with a saw cut at the apex of the junction; i.e., one blade thickness from
the inside edge of the slot corner, and this cut shall be to the same depth as the adjoining
slots. The junction shall not be truncated with a cold chisel. Slots cut for feeder cables shall
be 20 mm wide (core cables 25 mm) with a tolerance of 3 mm, to give a cover of 65 mm in
bituminous surfaces (45 mm in concrete surfaces) with a tolerance of + 10.0 mm / -0.0 mm.
Only one feeder cable shall occupy each slot.
6 The loop feeder cables shall take the most direct route to the indicated cable chamber. This
slot is specified as being 20 mm wide, therefore care shall taken not to obliterate any road
markings in whole or part. In the first instance the most direct route from the loop position to
the kerb line shall be taken. The loop feeder cables shall be joined in the carriageway only
with the approval of the Engineer. The joint slot shall be 10 mm wider and 10 mm longer than
the overall dimensions of the completed joint. The depth of the slot shall be sufficient to give
a minimum 40 mm cover above the joint. The joint slot shall be positioned either at a traffic
lane boundary or at crown of the road so that it is not subjected to the maximum stresses
exerted by road vehicles. Each loop shall be separated from adjacent loops by a minimum of
100 mm. The Contractor's supervisory staff shall check the quality of workmanship before
laying cable and backfilling. All debris and slit shall be cleared from the base of the slot and
the slot blown dry with compressed air before cable laying.
7 For laying loop cables the cable shall be dry before installation. The Contractor shall ensure
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that the cable lies evenly in the bottom of the slot, and shall secure the cable in such a
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position if necessary. Sharp implements shall not be used to seat the cable in the slot. Loop
tails shall not extend more than 20 metres from the loop before being joined to the feeder
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cable. Loop tails shall be twisted. Each twisted tail shall have a dedicated slot to the joint with
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feeder cable. Loop tails shall normally be joined to the feeder cable within cable inspection
chambers. Cables shall not be bent to a radius of less than 12 times their diameter or less
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than a radius recommended by the manufacturer whichever is the greater. Where cables
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enter the sidewalk a small area of carriageway is to be excavated and a uPVC duct laid
through the kerbs for each feeder cable. The duct shall be level with the base of the slot from
which the feeder cable emerges. The excavated area shall be backfilled with fine aggregate
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concrete to the duct invert level. The cables shall then be backfilled with compacted fine cold
asphalt and hot oxidised bitumen R85/40. The kerb stone shall be reinstated. Feeder cables
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in soft verge or beneath sidewalks are to be laid in ducts at a minimum depth of 500 mm
below ground level unless otherwise specified by the Engineer. Feeder cables laid unducted
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in trenches shall be laid on a 75 mm bed of sand free from stones and other sharp materials
with a further 75 mm of similar sand placed over the cable. Where feeder cables are laid
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unducted in soft verges, the cable position shall be indicated with a plastic warning tape laid
at a depth of 150 mm to 200 mm from ground level and vertically above the cable. The tape
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shall be printed with suitable warning message repeated at one metre intervals. Where
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feeder cables are required to cross French drains or other coarse bed materials in central
reservations, the cable shall be looped and protected with flexible plastic ducting. Ducting is
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to be provided by the installation Contractor.

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8 Cable joints shall be approved by the Engineer. Feeder cables shall be electrically connected
to the loop tails with insulated crimp connector using a ratchet type of crimping tool. The
Contractor shall ensure that the cable conductor has been correctly crimped by visually
checking the cable and also by applying a vigorous pull test to the cable on either side of the
joint. The electrical connectors shall be encased in a joint approved by the Engineer and the
Contractor shall ensure that the connectors are staggered to avoid the possibility of any short
circuits. The Contractor shall ensure that any instructions issued by the cable joint
manufacturer are provided in writing to his installation and supervisory staff. These
instructions shall form part of this specification. The Contractor shall ensure that the joint is
waterproof before backfilling. With the exception of cable joints between loop and feeder
cables, no other joint shall be permitted in the loop/feeder configuration. Cables shall be
terminated in the controller or detector housing using terminal connection blocks which are
adequate in size for the diameter of conductors used. Screws shall not bear directly onto
conductors, either a protective leaf in the terminal or a crimped pin on the end of the
conductor shall be used.
9 Immediately before backfilling, the Contractor shall ensure that all slots are clean and dry and
that all silt and debris has been removed from the base of the slot. Loop slots shall be
backfilled with a low viscosity epoxy resin, approved by the Engineer, to give a minimum of
10 mm cover above the uppermost cable. The resin specified shall be poured at a viscosity
of between 500 and 1000 pascal seconds. The Contractor shall provide the Engineer
documentary evidence from the resin manufacturer of the temperature necessary to achieve
this viscosity. The Contractor shall satisfy the Engineer, before epoxy resin operations
commence, that the specialist subcontractor’s on-site equipment is able to raise the epoxy
resin and maintain it at the temperature necessary to achieve the viscosity specified. The
remaining volume of loop slot shall be backfilled with blown grade hot oxidised bitumen to the
level of the road surface. Feeder cable slots shall be backfilled with fine cold asphalt
compacted around the cable. The upper 20 mm of the slot shall be filled with hot oxidised
bitumen. Joint slot shall be backfilled with epoxy resin to a level 10 mm above the completed
joint. The remaining volume shall be filled with hot oxidised bitumen. The hot oxidised
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bitumen specified shall be heated to a pouring temperature of 185 °C and shall be poured
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from an enclosed container which shall be preheated before use. The fine cold asphalt
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specified shall comply with the requirements of BS EN 13108. The asphalt shall be soft and
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easily worked when applied, and shall be hand compacted to the satisfaction of the Engineer.
Alternative compounds proposed by the Contractor shall be approved by the Engineer.
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The contractor shall be responsible in determining the exact location of the loops and shall
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supervise the work of the sub-contractor. The sub-contractor shall mark the locations of the
performed inductive loops. Each shall be separated from adjacent loops by a minimum of
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100mm and shall be laid on top of the road base or 230mm form the road surface.
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11 The cable shall be dry before installation. The sub-contractor shall lay the performed
inductive loops and stretch it as per the marked locations. The T-joint of the loops shall be
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positioned to the nearest chamber/pull box/detector hand hole. The loops shall be fixed by
using a clamps and nails to achieve the desired shape
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12 The loop wires from the preformed loop to the adjacent chamber/pull box/detector hand hole
shall be twisted together into a pair with minimum of three turns per 305mm and encased in
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polypropylene conduit and/or 2250 psi hydraulic hose between the performed loop and the
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adjacent chamber/pull box/detector hand hole. Lead-in conduit shall be 100% injected with
hot asphalt sealant to prevent the entrance of water at the chamber/pull box/detector hand
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hole.
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13 Asphalt shall be manually laid around the loops to protect it from the pavement
machine/equipment.
14 Upon completion of the installation works, the Contractor shall lay the asphalt on the entire
carriageways by using the approved pavement machine.
15 Each loop shall be tested sequentially by three methods: by megger (measured by mega
ohms), by resistance (in ohms), by inductance (measured in micro henries).
16 In case of existing pavement, a groove shall be cut by using a slot cutting machine. The
frames and home-runs shall be placed into the cuts. The cuts shall be filled with hot melted
asphalt-rubber sealant conforming to the manufacturer’s recommendations.
17 All the installation works shall conform to the manufacturer’s specifications.

16.4 TESTING AND COMMISSIONING
1 Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
acceptance test in his workshop. The programmed and internally complete controller shall
be connected to a labelled light board capable of simulating all traffic signal aspects
controlled by that particular controller. The Contractor shall ensure that all equipment and
devices are available to show that the controller fully complies with operational requirements.
The factory acceptance test shall consist of the following checks:
(a) visual check of internal wiring and controller assembly

(b) operation of green conflict monitor
(c) intergreen times
(d) group times
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(e) detector logic (where applicable)
(f) stage to stage change logic
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(g) lamp switching.
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All traffic signal equipment shall be commissioned to the satisfaction of the Engineer.
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3 It shall be the responsibility of the Contractor to supply all equipment and personnel required
to commission the traffic signal equipment.
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4 On completion of installation, and before commissioning, the Contractor shall undertake the
following tests to the satisfaction of the Engineer and in accordance with the QGEWC (E)
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Regulations.
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(a) visual inspection

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(b) continuity test of all protective conductors

(c) insulation resistance test; insulation resistance shall not be less than 100 megaohms
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(d) polarity check

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(e) earth loop impedance test.

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5 Where a residual current circuit breaker is installed, tests in accordance with the QGEWC
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(E) Regulations shall be complied with. The Contractor shall provide the equipment
necessary to complete the tests and shall provide all other test equipment to demonstrate
that the installation is compliant.
6 After the traffic signal and controller equipment is installed on site and after it is connected to
all its associated equipment, the Contractor shall arrange for a site acceptance test. The site
acceptance test will recheck all the points covered in the factory acceptance tests and in
addition shall include visual and electrical tests on all posts, gantries, heads, push-buttons
and cabling. The Contractor shall ensure that the area of site covered by the installation
being tested is cleared of all debris, plant and machinery. The Contractor shall be
responsible for the supply of any personnel required to conduct the site acceptance test. The
Contractor shall provide any vehicles required to conduct the site acceptance test. The
Contractor shall ensure that all equipment and devices are available to show that the
controller fully complies with the operational requirements.
7 Each loop and feeder configuration of the vehicle detection system shall be tested as follows
and the results given in a test certificate for the loop installation. This certificate shall include
all pertinent information for the testing. The Contractor shall submit a pro-forma certificate to
the engineer before carrying out the commissioning.
(a) With the loop circuit disconnected from the detector, the impedance to earth of the
two loop and feeder conductors shall be measured at a test voltage of 500V DC
applied for at least one minute. This shall not be less than 10 megaohms. The two
ends of the loop circuit shall be connected together for this test
(b) With the armouring of the feeder cable disconnected from the earth point, the
impedance to earth of the armouring shall be measured at a test voltage of 500V DC
applied for one minute. This shall not be less than 10 megaohms
(c) With the armouring of the feeder connected to the earth point of the equipment
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housing, the impedance to earth of the armouring shall be measured. This impedance
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shall not be greater than 0.5 ohms
(d) The inductance of the loop and feeder circuit shall be measured. This shall be
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comparable with the theoretical value previously supplied to the Engineer
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(e) The frequency of operation of each configuration shall be measured. Where two loop
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circuits share a common feeder cable their frequency of operation shall be separated
by at least 5 kHz
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(f) The Contractor shall adjust the sensitivity and presence time of each detector to the
requirements specified by the Engineer. The Contractor shall demonstrate correct
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operation of the detector at the sensitivity specified

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(g) The Contractor shall ensure that an inductance change caused by vehicles in one
loop shall not induce spurious observations in any adjacent loop system.
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8 Any loop or feeder which fails these tests shall be replaced by the Contractor at his expense.
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9 Upon satisfactory completion of the factory acceptance and site acceptance tests, and when
the Engineer is fully satisfied that correct installation and adherence to the operational
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requirements has been attained. The PWA will issue a final commissioning certificate. The
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installation, or any part thereof shall not be opened to general traffic until this certificate is
received.
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16.5 GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT
16.5.1 General
1 During the initial maintenance period complete record of component failures shall be kept by
the Contractor in order to provide information on the reliability of various components.
16.5.2 Operational Maintenance
1 The Contractor shall provide full operational maintenance coverage for a period of 400 days
subsequent to the issuance of the final commissioning certificate.
2 The Contractor shall use only maintenance contractors approved for this work by the PWA.
3 During the maintenance period, the Contractor shall be responsible for providing coverage for
the following:
(a) Replacement or repair and installation of any failed equipment

(b) Daily corrective maintenance
(c) Quarterly maintenance
(i) Check the cycle length, green time, intergreen time and all other signal timing
parameters as given in the timing chart.
(ii) Check the timings of the different signal programmes and test the switch over
them manually and by time clock.
(iii) Test loop detectors for activation and re-tune if necessary.
(iv) Test ELCB and any other circuit breakers.
(v) Replace any items that show significant wear and/or are operating outside of the
manufacturer’s tolerances.
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(vi) Test operations of pedestrian push buttons
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(vii) Check timing of Flashing Units
(viii) Service controller in accordance with manufacturer’s specifications
(ix) All signal heads, reflectors, optical lenses and backing boards shall be cleaned
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(both internally and externally) in accordance with the manufacturer’s
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specifications
(d)
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(Bi-annual maintenance - The following works are to be carried out in addition to those
described in section (c)
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(i) All protective earth conductors shall be inspected and tested.
(ii) All lamp fittings and connectors shall be dismantled and cleaned.
(iii) Signal heads shall be checked for correct alignment and all brackets and
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clamps tightened.
(iv) All electrical connectors are to be checked and cleaned where necessary.
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(e) Annual maintenance - The following works shall be carried out in addition to those
described in sections (c) and (d)
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(i) All signal poles and gantries shall be painted and renumbered. The signal poles
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and gantries shall be coated with primer, red-oxide, and two coats of colour grey
paint. The paint specification/colour shall be approved by the Engineer.
(ii) All inspection chambers shall be cleaned properly.
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(iii) Timings for all signals shall be altered as directed by the Engineer at the
beginning and end of the month of Ramadan.
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(iv) Minor changes to the controller’s operational configuration (Changing of phasing

/staging, green times and intergreen times) as deemed necessary by the PWA’s
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traffic signal engineer.

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4 The Contractor shall ensure that personnel are available to maintain equipment such that
failed equipment shall be replaced or repaired within four hours of notification of the fault.
Where controller configuration changes are required, the Engineer shall allow a reasonable
period for the Contractor to respond.
5 Failed equipment shall be replaced/repaired within 4 hours of notification of the fault.
6 Where controller configuration changes are required, the Engineer shall allow a reasonable
period for the Contractor to respond.
16.5.3 Emergency Maintenance
1 In the case of accidental damage or 'knock downs' or any other equipment failure deemed to
be outside of the Contractor’s control, shall not be required to take responsibility for repair or
replacement. However it shall be the Contractor’s responsibility to provide the immediate on-
site response to a police or the PWA request.
2 Upon the PWA having effected a remedy to any emergency maintenance requirement, it
shall be the Contractor’s responsibility to ensure that all repairs or replacements have been
conducted to a standard such that no warranties become invalid.
3 If the Contractor feels that any repair or replacement is not of sufficient standard to maintain
his warranty he shall notify the PWA with 14 days of any such repair or replacement having
been conducted.
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16.5.4 Contractor’s Vehicles
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1 The Contractor shall arrange a vehicle mounted hydraulic platform with boom and any
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additional vehicle for the use of his staff whenever required throughout the maintenance
period.
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The vehicles shall be provided with a flashing amber roof light array.
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3 The contractor shall be responsible for any cost associated with the vehicles.
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4 The hydraulic platform shall be capable of performing the required vertical and horizontal
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manoeuvres safely and satisfactorily, including adequate platform capacity and boom
articulation.
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5 The contractor shall gain approval from the Engineer as to the vehicle acceptability prior to
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supplying the said vehicle.
16.5.5 Contractor’s Equipment

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1 The Contractor shall be responsible for supplying any regular or special equipment or tools
required for the satisfactory undertaking of the works. In particular this shall include, but not
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limited to:
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(a) Specialised commission/testing equipment for all the current traffic signal (Siemens,
Futurit, Peek and Tyco) controllers to allow Factory Acceptance Tests (FAT) and Site
Acceptance Tests (SAT).
(b) Portable keyboard interfaces to allow interrogation and on-site programming of micro-
processor signal controllers for all the traffic signal systems.
(c) Workshop based aspect simulators to allow for Factory Acceptance Tests.
END OF PART
Part 17: Road Drainage
17 ROAD DRAINAGE................................................................................................... 2
17.1 GENERAL REQUIREMENTS .................................................................................. 2
17.1.1 Scope 2
17.1.2 References 2
17.2 DRAINAGE PIPES & PIPELINES ............................................................................ 3
17.3 EXTENDING PIPELINES ........................................................................................ 4
17.4 ROAD GULLIES ...................................................................................................... 4
17.5 MANHOLE COVERS AND GULLY GRATINGS ...................................................... 4
17.6 SOAKAWAYS ......................................................................................................... 5
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17.7 SOAKAWAY BOREHOLES ..................................................................................... 6
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17.8 TESTING AND CLEANING SURFACE WATER DRAINS ....................................... 7
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17.9 TRENCH SOAKAWAYS .......................................................................................... 7
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17.9.1 General 7
17.9.2 General 7
17.9.3 Pipe nt 7
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17.9.4 Geotextile Fabric 8
17.9.5 Single Sized Coarse Aggregate 8
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17.9.6 Catchpit Chambers 9

17.9.7 Road Crossings 9
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17.9.8 Geocellular Stormwater Attenuation / Soakaway Trenches 9

The maximum installation depth, to base of units, shall normally not exceed the
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height of 10
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17.9.9 Reinstatement above Trenches 10

17.9.10 Testing 10
17.10 GEOCELLULAR TANKS ....................................................................................... 10
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17.10.1 Geocellular Units 10

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17.10.2 Geocellular Tank Arrangement 10

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17 ROAD DRAINAGE
17.1.1 Scope
1 This Part includes:
(a) stormwater drainage works draining the road carriageway and directly adjacent areas,
including:
(i) road and other pavement gullies and gully pots
(ii) pipes of minimum 150mm diameter including bedding materials used to connect
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gully pots to inspection chambers and intermediate manholes
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(b) groundwater drainage using filter drains within the road corridor
(c) soakaways specifically related to road stormwater and groundwater collection and
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disposal
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(d) connections to stormwater drainage systems including culverts, open channels and
closed stormwater drainage pipelines.
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(e) Geocellular attenuation and soakaway trenches and tanks.

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This Section
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Part 18 Geosynthetics
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Section 5 Concrete
Section 8 Drainage Works
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Section 20 Drainage Works for Buildings

Part 3 External Drainage Works
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17.1.2 References
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BS EN 124 ..................Gully tops & manhole tops for vehicular and pedestrian areas
BS 4962 ......................Plastic pipes and fittings for subsoil drainage

BS 5911 ......................Concrete pipes ancillary concrete products
BS ISO 14654 ............Epoxy coated steel
ISO 9001 ....................Quality assurance in production and installation
BRE digest 365 - Soakaway Design

1 The manufacturer of all manholes and gully gratings shall be accredited to a third party
quality system such as ISO 9001. The supplier shall submit a copy of his accreditation
showing the scope of products covered.
1 All manhole covers and gullies shall be clearly marked with the technical standard of
manufacture, the loading class, the name identification mark of the manufacturer and the
mark of the certification body.
17.2 DRAINAGE PIPES & PIPELINES
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1 The materials, manufacture, finish, installation inspection and testing of all drainage pipes
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and fittings for roadworks shall comply with the requirements of Part 3 of Section 20, except
as modified by this section of the specification.
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2 The type of pipe to be used and the diameter shall be as designated on the drawings or in the
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project specification.
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Pipes may be of vitrified clay, concrete, glass reinforced plastic or UPVC. Each of these pipe
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types shall meet the designated requirements for standards, materials, manufacture,
strength, length and dimension of tolerances joints, workmanship and finish, inspection and
basis of acceptance given in Part 3 of Section 20.
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4 Unless designated otherwise only one type of pipe shall be used within any individual drain or
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service duct between consecutive chambers.
5 The Contractor shall ensure that plastic pipes are not subject to deterioration due to
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exposure to sunlight between manufacture and installation in the ground.

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6 The excavation, bedding, laying and backfilling around pipelines shall be carried out in
accordance with Part 2 of Section 8.
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7 Soft spots below the bottom of an excavation shall be removed as directed by the Engineer
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and the resulting void backfilled with granular material to the approval of the Engineer.
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8 Any additional excavation below the bottom of the line required shall be made good with
granular material.
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9 The pipes shall be laid at the designated levels and gradients. The deviation in level from
that designated at any point shall not exceed 20 mm unless agreed otherwise by the
Engineer.
10 Pipes shall be laid so that each one is in contact with the bed throughout the length of its
barrel.
11 Parts and fittings shall be examined for damage and shall be cleaned immediately before
laying. Any pipes that are damaged shall not be used in the works.
12 Measures shall be taken to prevent soil or other material from entering pipes and to anchor
each pipe to prevent moving before the work is complete.
13 The pipe bedding material shall be as designated on the project drawings or in the contract
documents.
17.3 EXTENDING PIPELINES
1 Where it is designated that existing drains are to be extended and connected to new drain
chambers or channel, the connections shall be made during the construction of the new
drain. The Contractor shall inform the Engineer in writing of the proposed position for the
connection and the detail of the connection. The position of the connection shall be recorded
by the Contractor on a drawing.
2 The new connecting pipe shall be aligned such that the angle between the existing pipe and
the new pipe is not greater than 60 %.
3 Before entering or breaking into an existing drain, the Contractor shall obtain approval from
the authority responsible for the pipeline.
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17.4 ROAD GULLIES
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1 The type, position, dimensions and clear openings of gullies will be as designated on the
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drawings or in the project specifications.
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2
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Gullies shall be constructed so that no part of the spout or trap has a cross sectional area
less than 2/3 that of the outlet.
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3 Precast concrete gullies shall comply with BS 5911 Part 2.
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4 Cast iron and steel gully gratings shall be kerb type gullies complying with BS EN 124 unless
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otherwise shown on the Contract Drawings.
5 The upper surface of gully gratings shall be flat except where otherwise designated. Slots in
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gratings or between gratings and frames shall not be orientated parallel to the direction of
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traffic, except where the slots are less than 150 mm long or less than 20 mm wide.
6 The frames shall be bedded on a 1 to 3 cement sand mortar.

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7 Backfilling to precast gullies shall be carried out to formation level with general fill. Where
mechanical compaction is impractical, the backfill shall be concrete of the designated grade.
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8 Gully connections shall be constructed of minimum 150mm diameter Unplasticised

PVC (PVC-U) pipes in accordance with BS 4660 or ESVC pipes in accordance with BS EN
295. Where required by the Engineer, these shall be bedded and surrounded with concrete
with movement at the joints permitted by the insertion of compressible material which shall
extend to the outside of the concrete surround.
17.5 MANHOLE COVERS AND GULLY GRATINGS
1 Manhole covers and gully gratings shall be formed from ductile iron with an element of
graphite spheres to produce a molecular structure that gives the required tensile strength and
shock load resistance.
2 Drainage products may be produced from grey iron and shall be hard wearing, inherently
stable and highly resistant to flexing.
3 The type of manhole cover; i.e., square, rectangular, double triangular, single cover shall be
as designated on the drawings.
4 During installation the frames shall be properly bedded and levelled to prevent rocking or any
lateral movement of the frame.
5 Covers and frames shall be kept together as a supplied unit and interchangeability between
various covers and frames shall not be permitted.
6 All castings shall be supplied with a black epoxy coating finish.
7 The tops of all manhole covers shall have a non-slip surface to provide adequate grip.
8 When so designated, the supplier shall arrange for specific lettering to be cast into the top of
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the covers. The lettering shall be up to a maximum of 4 letters or digits.
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9 Manhole covers and gullies shall meet the requirements of BS EN 124, European Standard
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for access covers of gully tops for vehicular and pedestrian areas.
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10 All manholes covers and gullies supplied shall have been verified as being manufactured to
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BS EN 124 by third party assessment body for both quality procedures and technical
requirements.
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11 The manholes’ covers or gullies shall meet one of the loading categories specified in BS EN
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124.
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Table 17.1
Loading Categories for Manhole Covers on Gullies
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Class Loading, Tonnes

A 15 1.5
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B 125 12.5
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C 250 25
D 400 40
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12 For a manhole entry to sewer and surface / ground water manholes a minimum of 750mm
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square clear opening shall be provided. For entry to TSE chambers a minimum of 675mm
square opening shall be provided.
13 For manholes situated in the carriageway a three point cover seating shall be adopted to
prevent any movement or rocking.
14 Where hinged gully gratings are installed the edge with a hinge shall face the traffic to ensure
the cover closes if inadvertently left opened and hit by traffic.
17.6 SOAKAWAYS
1 Soakaways shall be constructed using precast concrete rings. Concrete works shall comply
with the requirements of Section 5 of the specification. Concrete shall be Grade C50 for the
precast concrete rings and the cover slab, using Sulphate Resisting Portland Cement.
2 The cover slab shall be of the dimensions and contain the reinforcement as shown on the
drawings or detailed in the Project Specifications.
3 The structural concrete shall be designed for durability and shall include as a minimum the
following specification:
(a) minimum cover 40mm

(b) all surfaces to be painted with an epoxy protective coating meeting the requirements of
Section 5 Part 14 of the specification. The protective coating shall be factory applied
to precast elements.
4 The soakaways shall have an internal diameter of 1.8 m unless otherwise designated and
shall be of a minimum depth of 3 m unless otherwise designated.
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5 The precast concrete rings shall be at least 150 mm thick and shall have three evenly spaced
lifting points.
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6 No permanently embedded metal parts shall be left with a cover less than 40 mm from the
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surface. The precast rings shall be constructed with 50 mm diameter holes at 400 mm
centres in rows spaced 300 mm apart. The holes shall be alternately offset.
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7 The bottom ring shall be founded on insitu blinding concrete 200 mm deep.
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8 The soakaway shall be surrounded by granular material which shall infill the whole void
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between the soakaway and the undisturbed ground around the excavation.
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9 The granular material shall be laid in tamps in 150 mm layers and shall nowhere be less than
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225 mm in width.
10 The granular material shall be clean durable, sharp-angled fragments roughly cubical or
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pyramidal in shape, of un-weathered rock of uniform quality graded and tested in accordance
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with Tables 14.3, from a source approved by the Engineer

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11 Cast iron covers and frames shall be to BS EN 124 of the designated loading class.
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12 Geotextile material lining to the outside of the soakaway excavation shall be in accordance
with Table 17.2 of this Section. The placing and laying of the material shall be in accordance
with the manufacturer’s instructions and Part 15 of this Section.
13 The geotextile material shall not be left exposed to the sun for a period greater than 7 days
before burying.
17.7 SOAKAWAY BOREHOLES
1 The Contractor shall drill soakaway boreholes at the locations shown on the drawings. Unless
designated otherwise the boreholes shall be 150mm diameter.
2 Boreholes shall be initially taken to a depth of 20 m. At this depth the borehole shall be
thoroughly flushed clean using compressed air and clean water.
3 The borehole shall then be completely filled with clean water and the rate of dissipation
recorded. If the rate of dissipation is found to be less than required by the design criteria
given in BRE digest 365 - Soakaway Design then the bore holes shall be deepened in 5 m
depth increments and flushed until a satisfactory rate of dissipation is recorded. At the
Engineers discretion the rate of dissipation maybe verified by a constant head permeability
test using proprietary equipment to monitor and record the flow rate and the variation in water
level within the borehole.
17.8 TESTING AND CLEANING SURFACE WATER DRAINS
1 Before completing of the road drainage part of the Works the Contractor shall systematically
clean the whole road drainage system, in accordance with Section 8, Part 10, including
gullies, connecting pipes and soakaways. The entire system shall be clear of debris and silts
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and in a sound working order.
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2 Cast iron covers shall be freed from surfacing materials and pivot points shall be greased.
The Contractor shall be responsible for cleaning up any silting of the surface water drainage
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system caused by other Contractors working within the Site and the approval of the
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Employer.
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A CCTV survey shall be carried out of the completed system in accordance with Section 8,
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Part 10 of QCS.
17.9 TRENCH SOAKAWAYS

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17.9.1 General
1 Trench soakaways shall be constructed in accordance with the dimensions and grades
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shown on the Drawings. The trench soakaway consists of a perforated pipe or geocellular
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units laid in a trench. A geotextile fabric lines the trench or surrounds the geocellular units,
with the remaining voids being filled with single sized coarse aggregate.
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2 Reinstatement of trench soakaways shall be in accordance with the Contract drawings.

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17.9.2 General
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1 Excavation for the trench shall be in accordance to the requirements of Part 3 of this Section.
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17.9.3 Pipe
1 The pipe shall be a 300mm UPVC for installations outside the carriageway and 300mm
ESVC for installations within the carriageway, perforated pipe supported on single-size
coarse aggregate bedding. Pipe perforations shall be 10mm diameter in staggered rows
around the circumference of the pipe with a pitch of 40degrees. The longitudinal spacing
between each row of holes shall be 200mm.
2 The manufacture, distribution, laying and jointing of perforated pipes shall generally be in
accordance with the requirements of Section 8.
17.9.4 Geotextile Fabric
1 Filter fabric material lining shall be non-woven geotextile manufactured from UV stabilised,
high tenacity, virgin polypropylene fibres that have been both mechanically and thermally
bonded and in accordance with Table 17.2.
2 The placing and laying of the material shall be in accordance with the manufacturer’s
instructions and Part 15 of this specification.
3 The geotextile material shall not be left exposed to the sun for a period greater than 7 days
before burying.
Table 17.2
Properties of Geotextile Material
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Mean Value
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Property Test Method Unit (Applied
(a)
Tolerance )
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Tensile Strength EN ISO 10319 kN/m 8.0 (-0.8)
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Tensile Elongation EN ISO 10319 % 60 (±20)
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CBR Puncture Resistance EN ISO 12236 N 1500 (-150)
Cone Drop EN ISO 13433 mm 38 (+6)

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Pore Size – Mean AOS EN ISO 12956 µm 75 (±20)

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2
Permeability – (H50) EN ISO 11058 l/m s 90 (-27)
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2
Weathering 50MJ/m Exposure (1 month EU) EN 12224 % >90
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Microbiological resistance EN 12225 % No loss

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Resistance to acids & alkalis EN 14030 % No loss

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Oxidation at 85 days (100 years) EN 12226 % >90

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Thickness @ 2kPa EN ISO 9863-1 mm 1.1

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(a)
Note: Applied tolerances are based on 95% Confidence limits
17.9.5 Single Sized Coarse Aggregate
1 The trench shall be filled by granular material, which shall infill the whole width of the trench
between the undisturbed ground trench sides, or between the geocellular units and the
undisturbed ground, as shown on the drawings. The granular material shall be laid and
tamped in 150 mm layers using mechanical plate compactors. For geocellular unit trenches
the backfill shall be brought up in even layers such that the backfill material does not differ by
more than 150mm in level between sides.
2 Where geotextile fabric is required to interface between the trench side walls and subgrade
and the soakaway trench fill material, the width of the geotextile must include sufficient
material to conform to trench perimeter irregularities and for a 150mm top overlap. When
overlaps are required between rolls, the uphill roll should lap a minimum of 500mm over the
downhill roll in order to provide a shingled effect. Care shall be exercised to prevent natural
or fill soil from intermixing with the trench granular material. All contaminated granular fill
shall be removed and replaced with clean material.
3 The granular material shall be clean, durable, sharp-angled fragments roughly cubical or
pyramidal in shape, of un-weathered rock of uniform quality and meet the grading limits in
Table 17.3. The materials source shall be approved by the Engineer based upon the
properties of the materials in accordance with the testing requirements as per Table 17.4.
No reactive carbonate rock or sources with indication of local ground water contamination
shall be used.
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Table 17.3
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Grading Limits for Granular Material
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BS sieve size (mm) % passing by weight
37.5 nt100
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20 60 - 90
14 5 - 30
10 0.2 - 1
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5 0
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17.9.6 Catchpit Chambers

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1 Catchpit chambers shall be constructed to the dimensions and at the spacing shown on the
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drawings.
2 Chambers shall consist of rectangular precast concrete sections with internal dimension 800
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x 1500mm. All concrete works shall comply with the requirements of Section 5 of the
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specification. Concrete shall be Grade C50. Sulphate Resisting Cement shall be used.
Chambers shall also conform in all respects to the requirements for surface water drainage
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manholes in Section 8.
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3 All surfaces to be painted with an epoxy protective coating meeting the requirements of
Section 5 Part 14 of the specification. The protective coating shall be factory applied to
precast elements.
17.9.7 Road Crossings
1 Where the trench soakaway crosses a road then non-perforated pipe shall be used extending
1.0 meters beyond the road kerb line.
17.9.8 Geocellular Stormwater Attenuation / Soakaway Trenches
1 Loads on modular geocellular unitsThe permanent vertical loads to be carried by the units
shall be determined by the designer
(a) Lateral loads

(b) Maximum installation depth
17.9.9 The maximum installation depth, to base of units, shall normally not exceed the height
of Reinstatement above Trenches
1 Reinstatement material above the trenches shall be of suitable fill, cement bound granular
material, foamed concrete pavement materials or asphalt, or as appropriate in accordance
with the Contract drawings, and shall be constructed in accordance with QCS Section 6.
17.9.10 Testing
1 On completion of each length of trench soakaway the Contractor shall carry out an infiltration
test. The test shall be carried between completed catchpit chambers. The 2 No. upstream
outlet pipes within the catchpit chamber shall be sealed and the chamber filled with water to a
minimum depth of 1.5 metres. The depth of water shall be recorded each hour for the first
twelve hours of the test and subsequently at time intervals as directed by the Engineer.
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2 The Contractor shall record the results of the test on a standard proforma and present these
to the Engineer on completion.
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17.10 GEOCELLULAR TANKS
17.10.1 Geocellular Units nt

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1 Geocellular units used to form storm water attenuation tanks and soakaway tanks shall be in
accordance with clause 14.9.8.
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17.10.2 Geocellular Tank Arrangement

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1 Locations for geocellular tanks

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Geocellular tanks made up of geocellular units are suitable for installation in the following
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locations:
(a) Public open spaces: beneath landscaped areas and paths. The landscaping scheme
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for the park shall be considered when assessing the loads upon the tank.
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(b) The vehicular access to the tank shall be restricted so as to exclude large vehicles, in
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excess of the design vehicle load, from the area above the tank.
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2 Loads on modular geocellular units

The design of tanks constructed using modular geocellular units shall:-
(a) take account of all applied loads, including accidental loading

(b) be based on appropriate laboratory tests
(c) use appropriate factors of safety
(d) analyse all appropriate limit states (or failure modes)
The determination of the loads to be carried by the geocellular units shall be determined in
accordance with the requirements of BD 31/01.
3 Permanent loads.
4 Accidental loads
The risk of accidental loading occurring shall be assessed in the design process. Public
parks may be occasionally inadvertently trafficked by HGVs and landscaped area can be
used to park cars. Hard paved area shall be assumed liable to support such occasional
accidental loading and geocellular tanks shall be designed to support accidental loading
without risk of collapse.
Location Risk
Landscaped area in Specialist vehicles used for maintenance of geocellular tank and
public park any separation system upstream of the tank
Illegal parking of private vehicles
Movement of delivery vehicles to kiosks in parks
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Large vehicles used for routine maintenance within park
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Specialist vehicles used for erection / maintenance of lighting
systems
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Erection of marquees / tents / stages / portable cabins for public
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events
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Large vehicles delivering equipment for public events
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Cranes for installation of equipment
Generators used for public events
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Planned parking of private vehicles during public events

Access for emergency vehicles – fire engines
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If the tank has not been designed to carry accidental loading then special precautions may be
required to prevent it occurring. In public parks, the area above a tank shall be fenced off or
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have other barriers / landscaping to prevent vehicle access. Warning signs shall be provided
to state that there is an area with limited load bearing capacity and restricted access for
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vehicles.
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The location of the tank and any loading restrictions shall be clearly identified in the operation
and maintenance manual for any facility.
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5 Lateral loads
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The lateral loads on the units due to earth and water pressure shall be assessed and allowed
for by the designer in accordance with the requirements for the design of retaining walls
given in BS 8002:1994.
6 Flotation or uplift
Where the tank system is located below the water table, the uplift force shall be resisted by
the dead weight of fill above the tank. Other surcharges that are not permanent shall not be
included in the assessment.
The minimum factor of safety against flotation shall be 1.25.
7 Minimum cover
The minimum cover to units shall be as follows:
Landscaped areas: a minimum of 1.0m to allow for suitable planting over the tank.
The design of landscaping should be undertaken at the same time as the design of the tank
so that the impact of tree roots can be considered. Trees should not be located closer than
the canopy width at mature height from the tank. Trees should not be planted directly over a
tank or in such a position where maintenance work would require the removal of the tree.
8 Maximum installation depth

The maximum installation depth, to base of units, shall normally not exceed the height of
three units, plus the cover as assessed in Sub-Clause 15.
9 Limit state design
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Modular geocellular tanks shall be designed as structural components, using limit state
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structural design theory in accordance with Section 4.1 of CIRIA Report C680 and BD 31/01.
The design philosophy shall follow the requirements for geotechnical design practice as
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described in Eurocode 7 (BS EN 1997-1:2004).
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END OF PART
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Part 18: Geosynthetics
18 GEOSYNTHETICS ........................................................................................ 2
18.1 GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS ........................ 2

18.1.1 Scope 2
18.1.2 References 2
18.1.3 Submittals 3
18.1.5 Guarantees and Warranties 4
18.2 REQUIREMENTS FOR GEOTEXTILES ....................................................... 4
18.2.2 Drainage Applications 5
18.2.3 Earthworks Applications 6
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18.3 GEOGRIDS ................................................................................................... 7
18.3.1 General Requirements for Geogrids 7
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18.3.2 Material Requirements for Geogrids 8
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18.3.3 Installation of Geogrids 9
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18 GEOSYNTHETICS
18.1 GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS
18.1.1 Scope
1 This part of the specification covers the use of geotextiles and geogrids for the;
(a) reinforcement of unbound aggregates for roads, hard standing and airfield pavements
(b) reinforcement of embankment foundations over soft or weak soils
(c) reinforcement of steep earthwork fills
(d) reinforcement of retaining walls and bridge abutments
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(e) repairs to earthworks embankment failures and landslides
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(f) for erosion control of slopes
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(g) for subsoil and sub-base drainage.
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This Section nt
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Part 3 Earthworks
Part 4 Unbound Pavement Materials
Section 8, Drainage Works
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18.1.2 References
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1 The following Standards and other documents are referred to in this part:
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ASTM D 751 ...............Test Methods for Coated Fabrics

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ASTM D 5034 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
(Grab Test)
ASTM D 5035 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
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(Strip Method)
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ASTM D 4533 .............Test Method for Trapezoidal Tearing Strength of Geotextiles

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BS 8006......................Code of practice for strengthened/reinforced soils and other fills

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BS 2782......................Method of testing plastics

BS 3502......................Symbols for plastics and rubber materials
BS 4618......................Recommendations for the presentation of plastic design data
BS EN ISO 10321 ......Geosynthetics
BS EN ISO 10319 ......Geosynthetics
DIN 54307 ..................CBR Test

DIN 53854 ..................Weight Test
DIN 53855 ..................Thickness Test
ISO 9001 ....................Quality Management and Quality Assurance Standards
Published Document (PD) 6533, Guide to Methods for Assessing the Durability of
Geotextiles, British Standards Institute.
18.1.3 Submittals
1 The manufacturer shall submit comprehensive test results for the geosynthetic for the
designated tests, which shall clearly indicate whether the values are mean values measured
in current production or minimum values which the property does not fall below.
2 The manufacturer’s submittal shall clearly state:
(a) the type of material, (whether a polyethylene, propylene or other)

(b) its structure whether (a monofilament, multifilament or other)
(c) the element of manufacture by one or combination of the following processes:
(i) Heat bonding.
(ii) Chemical resin bonding
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(iii) Mechanical bonding.
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3 If the Contractor wishes to propose a material that has been tested to alternative standards,
the Contractor shall submit correlation tests showing the comparable values of the two test
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methods. These test results shall be comprehensive giving full details of the sample
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conditioning, preparation, method of test and criteria for assessment.
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The manufacturer shall submit comprehensive information of previous applications of the
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material in similar conditions and environments. This information shall include the project
name, contract details, type/grade of material used, quantity of material used, name of the
contract, client, consultant, and main contractor.
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1 The geotextile shall be supplied by a manufacturer who is certified to the ISO 9001. The
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Contractor shall submit to the Engineer a copy of the ISO 9001 certificate that clearly states
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the scope of the certification.
2 The geotextile shall be supplied by a manufacturer who provides technical assistance on the
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suitability for the application and installation for the material. For the initial use of the material
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on site, the Contractor shall arrange for the technical representative of the manufacturer to
be present to demonstrate the correct use of the material.
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3 Where feasible the jointing of geosynthetics shall be as prefabricated joints manufactured

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under factory controlled conditions. Joints made during the execution of the work shall be
kept to a minimum.
4 Joints shall be tested by the same test methods used for the main material.
5 All joints used in permanent structures designed to carry loads shall be tested in accordance
with BS EN ISO 10319 Part 1 or BS EN ISO 10321.
6 In situations where relatively small tensions are developed and, if permitted by the Engineer
overlapping joints may be used. These joints shall not be used in the primary tensile direction
of reinforced soil structures but can be in secondary tensile directions only.
7 Joints where geotextiles are sewn together shall be with one of the methods showing in
figure 5 of BS8006. These joints shall meet the performance characteristics shown in Table
8 BS8006.
8 Prior to delivery of the material to site the Contractor shall submit a sample of a sawn joint.
9 Bodkin joints shall have sufficient cross sectional area and strength to avoid excessive
deformation. A bodkin joint shall not be so large so as to distort the material causing stress
concentrations, bodkin joints shall be pretensioned prior to loading to reduce joint
displacement as the components lock together.
10 Any cuts, tears, splits and perforations to geosynthetics during installation shall be made
good. The method of remedial work shall be prepared and proposed by the Contractor for
approval by the Engineer.
11 The geosynthetics shall be suitable for use in the ambient soil temperature in the State of
Qatar.
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12 Geosynthetics that are able to ravel shall be heat treated or bonded with an adhesive tape at
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the cut. The proposed method of sealing the edges of geotextiles shall be proposed by the
Contractor and shall fully identify the geotextile material, type of scene, stitch configuration,
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stitch density, sowing thread and sowing machine to be used.
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18.1.5 Guarantees and Warranties
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The Contractor shall submit a ten-year guarantee for the geotextile material and the
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workmanship. The guarantee shall be worded to reflect the required performance of the
material and shall be approved by the Engineer.
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18.2 REQUIREMENTS FOR GEOTEXTILES

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1 All geotextiles shall be supplied in manageable roll or unit sizes and shall be robust enough
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to withstand handling and any treatment received during the installation process.
2 The geotextile shall comply with the minimum properties for geotextile serviceability in Table
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18.1 below. The Engineer will direct as to the category that the geotextile shall meet; i.e., very
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high, high, moderate or low.

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Table 18.1
Minimum Properties for Geotextile Service Ability
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Very
Property High Moderate Low
High
Grab Strength ASTM D 5034 1200 800 600 400

Puncture Strength Modified ASTM D-751/3787, N 500 340 180 135
Burst Strength 3.0 2.0 1.5 1.0
Trapezoidal Tear ASTM D-4533 340 225 180 135
These are the minimum required values below which no test result on production material
should fall.
3 The Engineer may require the Contractor to carry out tests to different standards, in addition
to the test methods designated above or in the following clauses:
(a) the manufacturer’s recommendations concerning the installation process shall be

strictly adhered to
(b) all geotextiles shall be suitable for use in the environmental conditions in the State of
Qatar
(c) geotextiles shall be resistant to deterioration on degradation from acids alkalis,
bacteria, brackish or saline water. The manufacturer shall submit comprehensive
results of tests carried out to demonstrate the durability of the materials under such
conditions. These tests shall involve checking the strength properties of the material
before and after prolonged exposure to typical groundwater conditions in the State of
Qatar
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(d) all geotextiles shall be protected from direct sunlight by storing inside the building or
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covering with heavy tarpaulins. Geotextiles shall not be exposed to direct sunlight for
a duration longer than 48 h
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(e) joints in Geotextiles shall be sewn where load transfer is required
18.2.2 Drainage Applications nt

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1 Geotextiles for drainage applications shall be needled polypropylene and meet the
performance specifications given in Table 18.2. The performance shall be assessed based
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on regular tests on the production material. Unless a permitted variation is stated in Table
18.2, the mean test values shall meet the values in the Table.
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Table 18.2
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Performance Specifications for Geotextiles for Drainage Applications

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International Classification
1 2 3 4
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According to CBR Test

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CBR test (DIN 54307)
mean value 10 % 780 1335 2695 4400

mean value minus standard deviation
10 % 700 1200 2450
deformation % 30 50 60 65
Tensile strength (ASTM D 5035)
longitudinal direction kN/m 10 % 3 7 12 25
longitudinal direction kN/m 10 % 3 8 14 35

International Classification
1 2 3 4
According to CBR Test
elongation at rupture % 35/45 50/60 45/55 90/65
Fall cone test hole diameter BS EN ISO

50 32 18 6.5
10319
Water permeability at 2 kPa mech. load

-2 -2 -2 -2
permeability coefficient cm/s 9 x 10 8 x 10 13 x 10 15 x 10
g
at 10 cm water column l/secm 30 %
2
150 90 80 45
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Pore size (unvibrated)
d 50% 80
nt 60 45 30
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d 90% 110 85 65 40
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2
Weight DIN 53854 g/m 100 140 250 500
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Thickness DIN 53855 mm 0.6 0.95 1.5 3.4

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2 The manufacturer shall clearly identify to which international classification category the
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geotextile conforms according to the CBR test.

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3 The pore size of the geotextile shall be small enough to prevent the significant loss of soil
particles from the retained soil, yet have adequate permeability to allow water transmission
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normal to the plain of the geotextile.
4 The manufacturer shall submit test results that demonstrate the ability of the geotextile to
avoid clogging during water flow due to fine particles. Test results for the US Corps of
Engineers gradient ratio test or similar type of test shall be submitted. The test shall be
carried out using soil of the type where the geotextile is to be installed. Gradient ratios
derived from the test shall be less than 3.
18.2.3 Earthworks Applications
1 Geotextiles for earthworks reinforcement or base use shall be woven polyester multi-filament
or multi-filament fabrics with a high rupture strength and low axial strain. The geotextile shall
have an adequate high tensile strength in all directions to resist loading imposed by uneven
filling.
2 The geotextile shall possess the strength for the required design life with minimal increase in
strain over time. The average geotextile strain shall be limited to 5 %.
3 Where installed between a sub-base and the underlying soil, the geotextile shall prevent the
granular material being pressed into the subsoil and also prevent an intrusion of fines from
subgrade into the sub-base.
4 The water permeability of the geotextile shall prevent build up of water pressure under the
separation layer. The short- and long-term permeability of the geotextile must be equal to or
greater than that of the subsoil. The geotextile must not become blocked.
5 The geotextile shall possess high puncture resistance and a high tearing resistance.
6 Where used as base stabilisation for embankments the type of construction equipment used
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for spreading and compacting initial fill layers shall be suitable so as to avoid damage to the
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geotextile. The initial layer of fill placed on the geotextile shall be free from sharp angular or
pointed material that may puncture the geotextile.
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7 Trucks shall not be permitted to drive over the geotextile. The laying of the material shall be
co-ordinated to ensure that trucks do not damage the material.
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18.3 GEOGRIDS
18.3.1 General Requirements for Geogrids

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1 The geogrid shall be identified as either uniaxial for single dimension loading or biaxial for
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two dimensional loading.

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2 The design of all geotextiles or geogrid applications shall be based on an appropriate in soil
temperature for the state of Qatar.
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3 The type of geogrid to be used shall be as shown on the drawings or as described elsewhere
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in the contract documents.

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4 The type of polymer used in the manufacture of the geogrid shall be clearly stated.
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5 The design shall take into account any possible damage to the material during site
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installation and a factor shall be introduced into the design.
6 Prior to installing the geosynthetic the Contractor shall prepare a construction trial outside of
the permanent works. The construction trial shall utilise similar ground conditions from
materials and other factors as the permanent works.
7 If directed by the Engineer the Contractor shall arrange for geotechnical investigation to be
carried out in the area where the geosynthetics are to be installed. The range and details of
the tests and investigations to be performed shall be directed by the Engineer.
18.3.2 Material Requirements for Geogrids
1 Geogrids shall be manufactured from a continuous sheet of polyethylene or polypropylene

which is punched with a regular pattern of holes. The sheet shall be heated and stretched so
that randomly orientated long chain molecules are drawn into an order and align state to
increase tensile strength and tensile stiffness.
2 The bars or ribs of the geogrid transverse to the direction of primary loading shall provide a
series of bearing points or anchors such that stress is transferred to the grid by surface
friction and also interaction.
3 The ribs of the geogrid in both the longitudinal and transverse direction shall be
manufactured to a near vertical face to provide good bearing surface for interlocking fill
particles.
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4 Geogrids shall be resistant to deterioration by aqueous solutions of acids, alkalis and salts,
petrol, and diesel fuel.
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5 Geogrids shall not be susceptible to hydrolysis, environmental stress, cracking or micro
biological attack.
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The manufacturer shall supply test results for load against strain for the material identifying
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all test conditions including strain rate and temperature of materials tested and test method.
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7 The Contractor shall submit full technical details of the geogrid proposed for use in the works.
These details shall include the following:
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(a) grid dimensions

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(b) thickness of longitudinal and transverse ribs

(c) strength of the material determined as stress strain, at strains of 2 and 5% both
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(d) transverse and longitudinally in accordance with BS EN ISO 10319

(e) weight in kilograms per metre squared for material
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(f) the supplied roll of dimensions

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(g) the minimum amount of carbon black tested in accordance with BS 2782 Part 4
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(h) the approximate peak strain , expressed as a percentage

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(i) the creep of the material under load determined in accordance with BS EN ISO 10319
for strain shall not exceed 10%
(j) the cross sectional shape of the ribs and of the rib joints.
All test results shall be expressed as a lower 95% conference limit in accordance with ISO
2602.
8 The Contractor shall submit test results for the durability of geogrids. Tests shall be in
accordance with PD 6533, - Guide To Methods for Assessing the Durability of Geotextiles.
9 The Contractor shall submit laboratory test results for prolonged exposure tests at similar
temperatures.
10 For each batch or delivery of the geosynthetic the Contractor shall submit the production
quality control test results shall be clearly related to batches delivered to site.
18.3.3 Installation of Geogrids
1 Prior to placing geogrids the Contractor shall prepare a detailed method statement for the
sequence of operations.
2 The methods employed shall ensure that the geosynthetic does not suffer deterioration
during placing and that any joints are formed effectively.
3 The handling and placement and installation of geogrids shall be carried out strictly in
accordance with the manufacturer’s recommendations.
4 Where the geogrid has been protected by a wrapping resistant to ultraviolet lights attack no
further protection against sunlight is necessary.
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5 For geogrids, jointing shall be by a bodkin whereby two overlapping sections are coupled
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together using a bar passed through the aperture of the grid. Joints shall be formed at the
highest mechanical and durability efficiency possible.
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6 If necessary the Contractor shall construct a temporary access road to the site location at a
convenient location close to the works, the Contractor shall prepare a clean working platform
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in storage area to accommodate geosynthetic materials.
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7 The geogrid shall extend across the full width of the embankment or area being treated in
one continuous piece and no part bits of rolls shall be used. This shall be accommodated by
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increasing the lap lengths.

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8 Prior to installation of the geogrid , the site shall be cleared in accordance with part 2 of this
specification
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9 Before placing geogrid any abrupt changes in ground profile should be levelled.
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10 Any regulating layer of fill placed shall not impair the vertical hydraulic conductivity of the
natural ground.
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11 Geogrids supplied in rolls shall be supported at a minimum of 2 points to prevent excessive

bending unless a central steel tube is used for support.
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12 Site handling of geogrids shall ensure that damage to the product such as surface abrasions,
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splitting, notching or tearing is prevented.
13 The installation of the geogrid shall be consistent with the direction of major stress.
END OF PART
Part 19: Miscellaneous
19 MISCELLANEOUS ........................................................................................ 2
19.1 STONE PITCHING ........................................................................................ 2

19.1.1 Scope 2
19.1.2 References 2
19.1.3 Submittals 2
19.1.4 Materials 2
19.2 GABIONS & PROTECTION MATTRESS ...................................................... 3
19.2.1 Scope 3
19.2.2 References 3
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19.2.4 Specific Requirements for Gabions 5
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19.2.5 Specific Requirements for Protection Mattress 5
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19.3 BOLLARDS .................................................................................................... 6
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19.3.1 Scope 6
19.3.2
19.3.3
References
Concrete Bollards nt 6
6
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19.3.4 Steel Bollards 7
19.4 RUMBLE STRIPS .......................................................................................... 7
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19.4.1 Scope 7
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19.4.3 Construction 7
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19.5 SPEED CONTROL HUMPS .......................................................................... 8

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19.5.1 Scope 8
19.5.2 General 8
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19.5.3 Construction of Speed Humps 9

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19 MISCELLANEOUS
19.1 STONE PITCHING
19.1.1 Scope
1 Stone pitching slope treatment shall consist of the placement and grouting of stone pitching
on slopes at the designated locations or at the locations directed by the Engineer to the
designated lines, grades, thickness and cross-sections or as directed by the Engineer.

This Section
Part 3 Earthworks
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19.1.2 References
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1 The following standards are referred to in this Subpart:
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AASHTO T96 .............Resistance to Abrasion by Use of the Los Angeles Machine
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BS 812 Part 2 .............Testing Aggregates - physical properties
BS 1881......................Methods of testing concrete
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19.1.3 Submittals
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1 Samples of the stone to be used shall be submitted to and approved by the Engineer before
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any stone is placed. These samples shall be kept on site and used for reference purposes for
the quality control of delivered material during the work.
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19.1.4 Materials
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1 Stone for pitching shall be hard, sound, durable, erosion resistant rock or cobbles.
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2 The nominal weight of the stones shall be between 3 to 4 kg (corresponding to a size of

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about 240mm x 140mm x 100mm). The maximum weight of the stones shall be between 32
kg (corresponding to a size of about 420mm x 230mm x 200mm).
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3 Tests for specific gravity and absorption, shall be determined in accordance with BS 812 part
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2 Testing Aggregates - physical properties. The minimum apparent specific gravity shall be
2.5 and the maximum absorption shall be 3 %.
4 The stone shall not have an abrasion loss greater than 45 % when subjected to five hundred
(500) revolutions in a Los Angeles Abrasion Machine in accordance with AASHTO T96.
5 The size and shape of the stones shall be such to allow for proper placement. The widths of
the stone shall be not less than one and one-half times their respective thickness and lengths
of not less than two times their respective widths.
19.1.5 Installation
1 The bed upon which the stones are to be placed shall be excavated to the designated grades
and lines or as directed by the Engineer.
2 Prior to commencing any stone pitching operations the Contractor shall prepare a trial laying
of not less than 2 m by 2 m using the materials and methods proposed for the work. The trial
laying shall establish the aesthetic appearance of the work and shall be used for comparison
purposes for acceptance of the final work.
3 A footing trench shall be excavated along the toe of the slope as designated or as directed by
the Engineer. All footing trenches and excavations shall be approved by the Engineer before
placement of stones or concrete.
4 Subgrade or base shall be firm and well compacted and approved by the Engineer. A 50 mm
thick layer of mortar shall be laid on the subgrade as bedding for the stones.
5 Stones shall be placed so as to provide a minimum number of voids; larger stones shall be
placed in the footing trench and on the outside surface of the slope. The flattest face of the
stone shall be laid uppermost parallel to the slope. Spaces between larger stones shall be
filled with the smaller stones.
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6 The surfaces of the stone shall be cleaned of adhering dirt and clay and shall be moistened
immediately prior to grouting.
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7 The space between stones of stone pitching shall be filled with mortar consisting of one part
Portland cement and three parts of fine aggregate, and one-fifth part of hydrated lime with
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sufficient water to produce a workable mix as approved by the Engineer.
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8 Sand and cement shall comply with the requirements of Section 5. The compressive strength
of the mortar shall not be less than 15 MPa when tested in accordance with BS 1881 Part
108.
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9 Immediately after placing, the mortar shall be spaded and rodded into place with suitable
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spades, trowels or other approved method. All the voids between stones shall be completely
filled.
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10 The exposed surface of the rocks shall project not less than 1 cm and not more than 4 cm
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above the mortar surface. The mortared stone pitching shall be cured by an approved
method for a minimum period of four days. Immediately after the expiration of the curing
period, the exposed surfaces shall be cleared of all curing mediums.
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11 Joints will be provided at a maximum interval of 12 m. Joints shall comprise a gap in the
stone pitching of 15 mm. The method of forming the gap shall be to the approval of the
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Engineer.
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19.2 GABIONS & PROTECTION MATTRESS
19.2.1 Scope
1 This work shall consist of supplying, building and placing of stone-filled gabions or protection
mattress as slope or watercourse channel protection.

This Section
Part 3 Earthworks
19.2.2 References
1 The following standards are referred to in this Subpart:

BS EN 10244..............Testing zinc coatings on steel wire and for quality requirements
BS EN ISO 1461.........Hot dip galvanised coatings on iron and steel articles

BS 1052......................Mild steel wire for general engineering purposes
BS 1722 Part 16 .........Organic powder coating to be used as a plastics finish to components
and mesh
ASTM G152 and G153-----Practice for Operating Light-Exposure Apparatus (Carbon-Arc

Type) With and Without Water for Exposure of Nonmetallic Materials.
1 Gabion boxes and protection mattress shall be made of a hexagonal woven mesh of double
twisted hot dip galvanised steel wire. The nominal mesh size shall be 80mm x 100mm.
Details of type of mesh proposed for use shall be submitted to the Engineer for approval.
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2 Wire shall be coated with a minimum thickness of 0.55 mm of dark green or black PVC
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complying with BS 1722 Part 16 Organic powder coating to be used as a plastics finish to
components & mesh.
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3 Wire shall be capable of resisting the effects of immersion in sea water, exposure to
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ultraviolet light and abrasion, when tested for a period not less than 3000 h in accordance
with ASTM G152 and G153.
4
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The cages of gabion panels and protection mattress panels shall be selvedged to prevent
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unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of
not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for
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the wire core. Wire for selvedges and lacing shall otherwise comply with the same
specification for the wire used in the mesh.
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5 Non-metallic material such as extruded polypropylene for gabion boxes may be proposed, for
the Engineer's approval. Samples and manufacturer's certificates shall accompany the
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proposal. The Contractor shall demonstrate that non-metallic materials are suitable for use in
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the climatic conditions of Qatar.
6 Gabion and protection mattress dimensions shall be as designated. A tolerance of 5 % on

width and height, and 3 % on length shall be allowed.
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7 Gabions and protection mattress shall have diaphragms at 1 m centres.

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8 Wire used in the fabrication of the gabion and protection mattress shall be mild steel to BS
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1052 having an average tensile strength, before coating, of 380 to 500 MPa. The core wire
diameter shall be 3.0 mm before galvanising. Galvanising shall comply with BS EN 10244.
9 Non-metallic gabion and protection mattress cages of proprietary type shall be constructed
according to the manufacturer's instructions.
10 All the fixing and binding wires shall be coated with PVC layer complying with BS 1722 Part
16.
11 All Gabions and mattresses shall be laid over a layer of geotextile membrane Grade 3000 at
all times.
19.2.4 Specific Requirements for Gabions
1 Stones for gabion filling shall be hard, sound, durable and highly resistant to erosion. The
stone size distribution in each individual box shall be as shown in Table 16.1:
Table 16.1
Stone Size Distribution of Gabions
Size of Stones mm % of Total (by number)
80 - 125 7 maximum
125 - 200 88 maximum
200 - 250 5 maximum
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2 Gabions shall be placed and built to the designated lines, levels and patterns on a prepared
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horizontal foundation surface, excavated as required and compacted as directed by the
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Engineer.
3
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Gabion cages shall be securely wired together at comers and cages, and where there is
more than one course of gabions, the upper course cages shall be laced to the lower course.
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Before filling, the cage shall be in its permanent position and laced to adjoining previously
filled cages.
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4 Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
voids. Tie wires shall be fixed inside the compartments and the units tensioned in
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accordance with the manufacturer's instructions.

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5 The cages shall be overfilled with stones to allow for subsequent settlement and the lid laced
down with binding wire to the top of each of the four sides and to the top of the diaphragm
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panels.
19.2.5 Specific Requirements for Protection Mattress

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1 The material shall be supplied as a large sheet with partition panels at 1 m centres to form a
cellular structure with the sheet turned up to form the sides. A separate sheet shall form the
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lid.
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2 The cages of protection mattress panels shall be selvedged to prevent unravelling of the
mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0
mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core.
Wire for selvedges and lacing shall otherwise comply with the same specification for the wire
used in the mesh.
3 Stones for protection mattress filling shall be hard, sound, durable and highly resistant to
erosion.
4 The stone size distribution in each individual box shall be dependent on the design thickness
of the mattress as shown on the contract drawings.
5 The protection mattress shall be a special type of rectangular gabion with a large plan area to
thickness ratio that is divided into compartments by partition panels fixed to the base.
6 The thickness of the protection mattress, the installation slope and the panel size shall be as
designated. The Contractor may elect to use a manufacturer’s standard size of mattress that
is thicker than that designated.
7 Protection mattress shall be placed and built to the designated lines, levels and patterns on a
prepared foundation surface, excavated as required and compacted as directed by the
Engineer.
8 Protection mattress cages shall be securely wired together at comers and cages. Before
filling, the cage shall be in its permanent position and laced to adjoining previously filled
cages. Several assembled units should be placed in position and wired together at their
edges with the wire passed continuously through each mesh in turn with a double turn at
every second mesh.
9 Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
voids. Tie wires shall be fixed inside the compartments and the units tensioned in
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accordance with the manufacturer's instructions.
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19.3 BOLLARDS
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19.3.1 Scope
1 nt
Short metal or precast concrete bollards for traffic control in roads or pedestrian areas.
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2 Related Sections
Section 5 Concrete
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19.3.2 References
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1 The following standard is referred to in this Part:

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BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles.
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19.3.3 Concrete Bollards
1 The use of cast in-situ concrete bollards will not be permitted.

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2 Precast concrete bollards shall be constructed with the dimensions and details shown in the
drawings. The surface finish and colour of the bollards shall be as shown in the drawings, in
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the Project Specification, per the designated details or as directed by the Engineer.
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3 All concrete and steel materials and procedures for the precast concrete bollards shall
comply with the requirements of Section 5.
4 The minimum grade of concrete for bollards shall be C40. Bollards shall be constructed using
OPC cement to BS EN 197-1.
5 The minimum cover to all embedded steel items in the bollards shall be 50mm with a
tolerance of -0 mm and + 10 mm.
6 Where precast concrete bollards are specified the Contractor shall design the bollards such
that the durability is ensured for a period of ten years. The Contractor shall submit a
performance guarantee for the bollards for a period of ten years. The guarantee shall provide
for the replacement of the bollard in the event of any deterioration due to exposure to the
elements.
7 The supplier shall verify this by a design submission covering the concrete mix design,
special admixtures additives, cover to reinforcement type of reinforcement and protective
coating. The engineer shall approve the material and design for the bollard based on the
particular exposure of the location proposed for use.
8 Prior to production of the precast bollards the Contractor shall cast a trial bollard for approval
by the Engineer.
19.3.4 Steel Bollards
1 Metal bollards shall be constructed of steel tube with the dimensions, details, wall thickness
and height shown on the drawings or provided in the Project Specification.
2 The top of the bollard shall be ground free of any rough edges and fitted with a tight durable
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ultraviolet light resistant plastic top.
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3 All metal parts shall be hot dipped galvanised to BS EN ISO 1461 after fabrication.
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4 All metal parts shall also be painted to the colours and pattern as shown on the drawings or
directed by the engineer. The paint system shall be compatible with the hot dipped
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galvanising and shall provide a service free life for five years.
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5 Where designated, bollards shall be removable. This shall be achieved by casting a 4 mm
thick PVC pipe sleeve into the pavement. The bollard shall be a tight fit into this sleeve. If so
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designated or directed by the Engineer a locking facility shall be incorporated with the
removable bollard.
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19.4 RUMBLE STRIPS

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19.4.1 Scope
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1 Rumble strips to provide warning to drivers of vehicles that accidentally stray out of the
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carriageway.
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2 Related Parts
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This Section
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Part 5 Asphalt Works.

1 The Contractor shall arrange for a trial installation of a rumble strip to demonstrate the
methods and equipment to be used. Approval to proceed with the construction of the rumble
strips will only be permitted after the Engineer has approved this trial in writing.
19.4.3 Construction
1 Rumble strips shall comprise of shallow formed depressions in the wearing course of the
road shoulders. The depth, plan size and layout of the rumble strips shall be as designated or
2 Rumble strips shall be formed by one of the following methods:

(a) cold planing
(b) Removal shutter boards.

3 Cold planing of indentations in the wearing course in the shoulder shall be carried out in
accordance with the requirements of the cold planing of Part 5. Edges shall be square and
true and free from any loose material.
4 Rumble strips may also be formed by the use of removable shutter boards. The boards shall
be rigidly located on the base or binder course prior to laying the wearing course. The
method of fixing the strip shall be subject to the approval of the Engineer. The laying of the
wearing course shall be carried out in accordance with the requirements of Part 5. Care shall
be taken to ensure full compaction of material around the edges of the shutter boards. The
shutter boards shall be carefully removed not earlier than three days after the laying and
compaction of the asphalt.
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19.5 SPEED CONTROL HUMPS
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19.5.1 Scope
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1 Speed control humps to limit the speed of vehicles.
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2 Related Parts
This Section
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Part 5 Asphalt Works.
Part 9 Kerbs, Footways & Paved Areas.
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19.5.2 General
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1 Speed control humps shall only be installed at the locations designated on the project
drawings or specified elsewhere within the contract documents.
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2 All speed humps shall be identified by markings on the road surface. The layout of these road
markings shall be as the Qatar traffic control manual or as shown on the project drawings or
elsewhere in the contract documentation.
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3 The profile of the speed hump shall be as shown on the project drawings.
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4 The profile shall represent a smooth gradual rise in elevation.

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5 Speed humps shall be constructed of the same asphalt mix design as the asphalt wearing
course.
6 The use of prefabricated rubber section speed humps or steel checker plate filled with
concrete speed humps is not permitted.
7 Speed humps shall be designated as one of two types; for low speed pedestrian areas and
for high speed roads. Low speed pedestrian areas speed humps shall comprise of a ramp
within elevated section constructed of interlocking concrete paving blocks.
19.5.3 Construction of Speed Humps
1 The dimensions and construction details of speed hump shall be as shown on the drawings.
2 Prior to installation of the speed hump the surface of the wearing course shall be scabbled or
abraded to a rough irregular finish to ensure bond with the speed hump. Tack coat shall be
applied at the base.
3 Wearing course shall be hand laid for the speed hump. The wearing course shall be
compacted and finished to a smooth profile.
4 All the asphalt work for the speed hump shall comply with the relevant clauses in part 5 of the
specification. The final profile speed hump shall comply to the profile on the drawings to
within  6mm.
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5 Heavy traffic or construction plant shall not be permitted to drive over speed humps until
7 days after the construction unless the engineer permits otherwise.
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END OF PART
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QCS 2014 - Section 6 Road Works

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QCS 2014 - Section 6 Road Works

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QCS 2014 Section 06: Road Works Page 1

Part 01: General

1.1 RELATED DOCUMENTS & REGULATIONS

due to or which may become due to the Contractor.

commencing the Works.

1.2.2 Permanent Monuments

1.2.3 Setting Out

their positions or in other approved positions.

1.3 EXISTING GROUND LEVELS

4 Approved equipment shall be maintained on site at all times to:

(a) Determine the laying and rolling temperature of bituminous materials.

1.5 NUCLEAR DENSITY TESTING DEVICES

1 No person or company will be permitted to determine in-situ density by mean of a nuclear

1.6 TEMPORARY FENCING

1.7 ROAD OPENING

1.8 CONCRETE WORKS

1.9 STANDARDS AND CODES OF PRACTICE

2 SITE CLEARANCE .................................................................................................. 2

2.10.2 Underground Storage Tanks 8

2.10.4 Abandoned Pipes and Culverts 9

2.10.6 Grouting of Pipelines 9

2.10.7 Plugging of Pipelines 10

2.10.10 Drainage Inlets and Gullies 10

2.11 DISPOSAL OF MATERIALS.................................................................................. 10

2.1.1 Scope of Work

1 This Part includes:

This Section: Part 3 Earthworks

Part 11 Works in Relation to Services

Section 2 Building Demolition

1 The following standards are referred to in this Part:

BS 5228......................Code of practice for noise control on construction and demolition sites

BS 6187......................Code of practice for demolition

2 Structures and installations to be dismantled or demolished shall be surveyed by the

2 Services to unused installations shall be safely disconnected before demolition. Notification

of disconnection shall be given to the appropriate authorities.

protected and illuminated.

5 Precautions shall be taken to prevent leakage or formation of flammable, explosive,

unhealthy or environmentally hazardous gas or vapour.

impracticable the Contractor shall provide replacements at his expense.

2.4 CLEARING AND GRUBBING

2.5 REMOVAL OF STRUCTURES

shall also be removed if directed by the Engineer.

2.6 REMOVAL OF STREET FURNITURE

damage to the posts.

2.8 REMOVAL OF EXISTING PAVEMENTS

2.8.1 General Requirements

2.8.2 Cutting Back Pavement

2.8.3 Stockpiling Asphalt Pavement

2.8.4 Stockpile Site

pavement to the designated stockpile location.

include a suitable lockable gate for entry.

5 Maintenance responsibility shall include but not be limited to:

2.9 MEASURES FOR STATUTORY UNDERTAKERS

Clause 3.3) and compacted.

designated storage areas.

4 Materials not recovered for reuse shall be disposed of.

2.10.2 Underground Storage Tanks

2.10.3 Removal of Culverts

2.10.4 Abandoned Pipes and Culverts

2.10.5 Total Removal of Pipelines

4 Materials damaged in the process of recovery shall be repaired by the Contractor.

designated storage area and placed into storage.

2.10.6 Grouting of Pipelines

1 Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he